expert brugge 7 atd 2011

EXPERT status| 11/05/2011

Jose Gavira EXPERT Project Manager

7th ATD SymposiumBruge, 11th May 2011

EXPERT

European eXPErimental Re-entry Testbed


Outline

EXPERT objectives: Re-entry and Aerothermodynamic

Mission overview: Launch, trajectory and landing scenario

System architecture & driving environments

Development Status :

Payloads and Instrumentation

Vehicle and subsystems

Launcher and Russian elements

Conclusions


EXPERT the ESA test bed

From Experimental to Operational systems

TRL, Reliability, Performances

Class 1

Class 3

Class 2

Build from experience gained in past Build from experience gained in past projects projects --> ARD, X38> ARD, X38


EXPERT objectives

To obtain in-flight measurements of critical AD/ATD phenomena for:

– Validation of CFD tools– Validation of wind tunnel test facilities– Consolidation of ground-to-flight extrapolation methodologies

Reduce design margin and uncertainties

Provide a test bed for experimentation

To demonstrate re-entry technologies Ceramic and metallic hot structureSensors for ATD measurements

To improve and develop technologies for re- entry systems, increasing TRL

To provide European industry with flight experience in re-entry/transportation vehicles

CFD Ground Testing Facilities

In flight data ???


Mission overview

– Capsule conical shape & Blunt nose

– Lateral flat sides & Four fixed open flaps

– 1.6 m length & 1.1 m diam., mass 450 Kg

– Submarine Launched from the Pacific Ocean by VOLNA launcher

– Suborbital ballistic trajectory, at 100 Km with entry speed of 5km/sec.

– Soil landed in Russian

Kamchatka Peninsula

– Data stored in solid state,

crash resistant memories

EXPERT trajectory VOLNA Launcher

3-rd stage

PL zone

2-nd stagefuel tank

2-nd stage oxidizer tank

2-nd stage propulsionsystem1-st stageoxidizer tank

1-st stagefuel tank

1-st stage propulsionsystem


Trajectory overview


Launcher Environment

– 3-stage Launch Vehicle

– Mounted upside down inside 2nd stage

– Quasi-static loads of 8 g long. / ±2 g lateral

– Random loads 7 GRMS & Acoustic 134 dB

– High frequency shock dimensioning for equipment

– 2nd/3rd stage separation dimensioning for main structures:

– Rapid de-pressurisation

– Acoustic shock

– Low frequency structural shock


Re-entry environment

Heat flux distributions over time (w/m^2) as input to thermo-mechanical analysis

Mach 10

Mach 18

Mach 12

Mach 16 Mach 13.5

Heat flux distributions (w/m^2) as input to thermo-mechanical analysis


System Architecture

- TPS metallic and ceramic Nose and flaps

- Internal (cold) structure in Al Sandwich (IF with electronics, PLs and sensors)

- Sensors and instruments in TPS

- Descent and Landing System

- IF with launcher and rear insulation


Power subsystem

Power Control Distribution Unit

8 unregulated power supply lines, 22-33 V dcLatching Current Limiters for protection from

possible failures induced by usersEmbedded pyro control unit capable of

managing up to 14 pyro-linesAnti-Vibration Mounts (AVMs) needed to cope

with mechanical environment

Batteries : Li-Ion, procured from SAFT

Modular concept employing 8 off-the-shelf MPS176065 cells connected in series

300 Wh @ 20°C, 270 Wh @ 5°C, altogether

Charged two months before launch


Avionics system and SW

ON-BOARD SOFTWAREData Acquisition Unit main scheduler freq.

100 Hz

Common Payloads protocol (RS-422)

Data time-tagging with respect activation command


Scientific Payloads

Nose Ceramic CMC Nose cap Assembly

P/L #01 FADS Flush Air Data System

P/L #02 PYREX Nose Heating

P/L #03 PHLUX Catalysis

P/L #04 Natural transition

P/L #05 Roughness induced transition

P/L #06 SWBLI onto Flaps

P/L #07 SWBLI ahead of Flaps

P/L #08 Flap Heating

P/L #10 RESPECT Shock-layer chemistry spectrometry

P/L #11 Nose-TPS Step Junction

P/L #12 Base Flow

P/L #13 SFS - Skin Friction Sensors

P/L #15 Flying Winglet - Sharp Hot Structure “SHS”

P/L #18 Inter-metallic TPS Flight Experiment

Payloads and Instruments fully qualified


Payloads development

– CFD (Flux) analyses were iterated with thermo-mechanical analyses

(CIRA, VKI, TU Delft, ESA)

– Nonlinear thermo-mechanical analysis of TPS (Dutch Space)

– Material Samples and Payloads tests in L3K (DLR) and PWK3 (IRS) facilities

– Scale model tests in Longshot and H3 facilities (VKI)

– Flap tests at Scirocco (CIRA)

(IR Camera and flap sensors)


Payloads qualification

Plasma test

Aerodynamic test

Mechanical and

thermal test


– Flights Models (FMs) test campaign concluded

– FMs delivered and integrated in the vehicle

Payloads development


– Facility:– Scirocco 70MW Plasma Windtunnel Facility (CIRA Capua),

designed to qualify TPS on large scale subsystem level

– Test Article:– Full Scale ceramic EXPERT Flap

(MT-A Augsburg)

– Instrumentation:– pressure ports (DLR-IAS-HY, Cologne)– Thermocouples (DLR-IAS-HY, Cologne)– Flight IR camera

(RUAG, Zürich)

SCIROCCO Development test


PL07(CIRA)

PL06(DLR-IAS-HY)

PL08(RUAG)

– Understanding of Performance of Aerodynamic Control Surfaces is key to:

– Performance

– Reliability

– Safety of space planes

– EXPERT control surfaces are heavily instrumented by an international team

– Flight Data exploitation will be lead by DLR-IAS-HY

– Control Surface performance was critical at STS-1 due to incorrect prediction

PredictionsCIRA DLR-IAS-RF

Control Surface Instrumentation

SCIROCCO test Scientific Background


– Facility performed flawlessly (CIRA)

– Flap without degradation after test (MT-A)

– Instrumentation performed accurately (DLR-IAS-HY)

– Preliminary data shows qualitative agreement with predictions with respect to:

– Material performance

– Temperature characteristics (RUAG)– Flow direction features

Hardware after test

High speed during test

Infrared during test

SCIROCCO tests Campaign Results


– External Vehicle TPS is delivered to TAS-I(Nose, Flaps, Metallic Body and insulation)

– Internal cold structure delivered to TAS-I( Electronics and payloads integrated)

– Subsystems manufactured and delivered(Avionics fully tested)

– Subsystems , PLs and flight harness integrated(Anti vibration mounts developed and tested)

– Descent and landing system under manufac. (Engineering Model deployments tests performed)

Vehicle development status


Vehicle integration


Metallic TPS integration


Design temperature

in the area is 14800С.

The fabric did not loose its strength

Rear Thermal Insulation

Engineering tests


– Supersonic Parachute (SP), 2 stages

– Supersonic drogue deploy: M=1.8, 16 Km, 523m/s

– Main Parachute deploy: M=0.3, 4Km, max. 80 m/s

– Landing speed below 10m/s

Parachute system with 2 stages

Supersonic drogue deploy: M=1.8, 16 Km, 523 m/s

Main Parachute deploy: M=0.3, 4/3 Km, max. 80 m/s

Landing speed requirement lower than 10m/s

Descent and landing system

16km 3km


DLS Parachute deployment


DLS inflation test on the drogue


Main ParachuteDrop Test Description

– Helicopter– MI-8 Helicopter

– Flight Velocity at 25 to 50 m/s

– Payload deployed around 1800 to 1200 m– 440 kg mock-up

– Shape, Size, Material unknown

– Additional Drogue parachute required– To obtain test conditions for EXPERT Main Parachute

– Drogue deployed after 2 to 5 s

– Main Parachute deployment– 700 to 1000 m

– 60 to 70 m/s


EXPERT Vehicle Recovery scenario

EXPERT Team

LEO/GEO

LUTMCCEXPERT Team

406Mhz digital signal.COSPAST-SARSAT ConstellationGlobal satellite coverage to locate EXPERT vehicle.

121.5Mhz analog signal.Regional coverage with no dataencoded and worst accuracy.

LEO/GEO satellites. LEO satellites provide periodicCoverage of the entire earth.GEO satellites continuous coveragebellow 70 degrees

Local User Terminal

Mission Control Centre


Conclusions

Project Milestones

– Integration and functional verification to be concluded mid May

– System verification and environmental tests in May/ June

– Qualification Acceptance Review in July / August

– Vehicle and DLS delivery to Kamchatka

– Final integration and launch preparation

– Launch September 2011 (end of launch window)

– EXPERT is a key development for ATD activities and Re-Entry technologies in Europe and attracted world wide attention from the scientific community.

– Shall provide a much-needed boost to European scientics and industrial competence in ATD and Re-entry / transportation activities.


EXPERT Consortium

ESA project : Re-entry test bed for in-flight experimentationThales Alenia Space Italia as Prime Contractor

Sub-contractors from 6 European countries (I, A, B, CH, D, NL ) Set of 14 scientific payloads from European Institutes (I, D, B, CH, S, Nl, F)

Coordination of experiments performed by CIRA Makeyev SRC provides; Launcher, DLS and ground recovery operations

expert brugge 7 atd 2011

Technology

environmentsdevelopment

x38expert status

rear insulationexpert

expert objectivesto

stage launch vehicle

flight experience

subsystems launcher

launcher environment