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Jon Olansen, Morpheus Project Manager JSC Chirold Epp, ALHAT Project Manager JSC Greg Gaddis, KSC Morpheus/ALHAT Site Manager July 31, 2012
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Mee;ng Objec;ves
Brief KSC Leadership on:
Morpheus/ALHAT project introducJon Morpheus/ALHAT free-ight readiness Test plan at KSC KSC range safety and personnel safety KSC InsJtuJonal Readiness
Get concurrence to proceed with free-ight operaJons at KSC Not a design review
Morpheus Overview
Jon Olansen/PM Mike Baine/Chief Engineer Tim Crain/Flight Dynamics Lore Williams/SoRware Rob Morehead/Engine Design Joe Bibby/Media and Comm Greg Gaddis/KSC Test Site Manager
Steve Munday/Dep. PM Lee Wilson/Structures Kevin Dunn/Avionics Jeremy Hart/System T&V DJ Kroeger/Prop GSE Rich Comin/Safety
Jenny Mitchell/SE&I ScoQ Woodard/Power Systems Eric Hurlbert/Propulsion Colin Peterson/Vehicle Mgr Fred Shetz/Ground Data Sys Mark Welch/Ops Lead
Introduc;on
Morpheus is an autonomous, reusable rocket powered terrestrial VerJcal Take-o /VerJcal Landing (VTVL) vehicle for tesJng integrated spacecraZ and planetary lander technologies Autonomous Landing and Hazard Avoidance Technology (ALHAT) Project has advanced the technologies for autonomous precision landing and hazard avoidance. In FY12, AES and TDM Programs are sponsoring the integraJon and demonstraJon of ALHAT technologies on Morpheus, with relevant approach trajectories own at the KSC SLF. The integrated vehicle provides a testbed to develop, mature, rene, and demonstrate advanced technologies promoJng enhanced autonomy, reliability, safety, reusability, ISRU, precision navigaJon and safe landing technologies Successful implementaJon of these capabiliJes will enable access to landing sites that were previously considered to be too hazardous to risk a roboJc lander mission, much less a human mission.
Hot Fire 1
April 14
Hot Fire 2
April 19
Tether 1
April 25
Tether 2
April 27
Tether 3
May 3
Tether 4
May 4
Tether 5
June 1
Tether 6
Aug 31
Hot Fire 5
Feb 27
Tether 7
March 5
Tether 8
March 13
Tether 9
March 16
30 sec 40 sec Low pressure First test for Morpheus 1.5 condiJon at with new HD4 liZo Burn-through engine wire false alarm
55 sec Good 40 second hover with prop imbalance and tether eects
Hot Fire 6
April 2
Tether 10
April 5
Tether 11
April 11
Tether 12
April 18
5 sec 62 sec Short hold down Guidance and test on concrete control in liZo algorithm environment issue in Foot pads alJtude overheated
Tether 13 Tether 14 May 8 May 2 66 sec 62 sec Stable 45- Stable 45-sec sec hover hover with with good improved lateral stability lateral stability
Tether 15
May 10
Tether 16
June 11
Tether 17
June 18
RCS HF1
July 3
Tether 18
July 6
Tether 19
July 17
41 sec Stable 2-level hover at 5 & 8 with ALHAT targeJng & HDS tests
63 sec burn Jme Stable 2-level hover with ALHAT targeJng & HDS tests
31 tests of LOX/ 49 sec methane RCS Stable 2-level engines hover Range of igniJon AZer nominal condiJons tether ight (temperature, compleJon, spark duraJon) tested RCS engine acJve control
72 sec burn Jme Nominal 60- second hover (longest yet) Post-ight methane RCS test
Morpheus Accomplishments
Flight and ground soZware architecture matured; core services and execuJve complete; Jming and avionics data management; incorporaJng design for FDIR Acquired in-ight test data on sensiJvity of components to thermal and vibraJon environments TesJng and demonstraJon of aluminum tanks with cryogenic propellants DemonstraJon of integrated capability using an avionics architecture that has space ight equivalent components Autonomous GN&C during nal approach porJon of lunar descent and landing; precision landing
Power distribuJon; power management for propulsion system; baiery management Operator workstaJons, ground soZware and displays Propellant loading and launch operaJons Ground support equipment Landing trajectory operaJonal Jmeline
Demonstrated LOX/Methane propulsion in VTB; propulsion subsystem maturaJon including feed system and startup condiJons; LOX/Methane RCS engines for roll control; propellant management with mulJple tanks
Analysis/simulaJon tools Project processes, systems engineering and infrastructure Core team
FLIGHT OPERATIONS
MORPHEUS VEHICLE
Like any planetary launch and landing vehicle, Morpheus includes a vehicle, subsystems, opera;ons, and ground systems
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(b) (3)
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Laser (Leica) scans of as-built vehicle Tether/bungee characterizaJon Card-level power and avionics tests End-to-end gimbal poinJng calibraJons CG measurement and balancing
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S July 22 23
S 28 Vehicle Prep
KSC Test Campaign 0 (C0) KSC Test Campaign 1 (C1), 8/27 9/07 KSC Test Campaign 2 (C2), 9/17 9/28 KSC Test Campaign 3 (C3), 10/08 10/19
KSC Ops
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Vehicle data
Vehicle data is downloaded via a serial hardline aZer the test. The data is posted to SharePoint where the team can get to it. Quick-look plots are generated. Low rate data (1 Hz) is also recorded in the control center
High dollar project High reliability required Crew safety Mission cri;cal Expensive payloads High visibility Schedule constraints Costly replacement Paying customer Morpheus ShuQle, ISS, Orion
The scale of project rigor should always be adapted to the needs and scope of the project. Some aiributes will drive rigor but not equally for all processes.
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Tether Test
Autonomous Hazard Avoidance Iden;fy and land at safe site in landing eld with hazards (rocks, craters, slopes)
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KSC C0
IniJal Capability
KSC C1
Envelope Expansion
KSC C2
1.Demonstrate KSC TesJng Capability via Tether test 2.VerJcal Free-Flight (10-20m alt) 3.Free-Flight Slant Hop (50m alJtude, 40 m range) 4.Demonstrate repeatability of slant hop ight 5.High-AlJtude Hop (~100 m alJtude, 40 m range) 6.Hop with higher pitch-over rate (50m alJtude, 40 m range) 7.Demonstrate higher alJtude hover (above expected wind shear) 8.Demonstrate porJon of powered ascent 9.Characterize performance below aerodynamic instability condiJons 10.High alJtude hop with ALHAT data gathering 11.Demonstrate full HDP trajectory (or nearest HD4 analog) 12.Landing site re-designaJon (redes) during full HDP trajectory 13.Landing site redes during full HDP trajectory, with ALHAT sensors (open-loop) 14.Repeat previous ALHAT free ight to collect more open-loop data 15.Performance during HDP with ALHAT sensors closed-loop 16.Landing site redes performance during HDP with ALHAT sensors closed-loop
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Ship to KSC
LN2 Dewar LOX Dewars LNG Dewars Helium Tube Trailer Flex Hose & QDs Pressure Control Panel Etc.
Flight Ops
Launch/Landing Area North end of SLF Post
Landing
Ops
(Landing
Area)
Xport
to
LSC
VenJng
Unloading
Sang
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Range Safety
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Based on this data the 45th Space Wing determined the following risks levels:
EsJmated CasualJes (Ec)= 14.9 per million (worst case - weekday, dayJme) Must be less than 100 per million Maximum Probability of Impact (PImax) = 0.37 per thousand Eastern Range approved Must be less than 1 per thousand
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Control Room IdenJes Limit ViolaJon If Vehicle Violates On-Board Limits (Velocity)
Control Room Commands SoZ Abort to Land Immediately Vehicle Detects ViolaJon
Vehicle Lands
Range Safety Remote Flight TerminaJon is a Last Resort aZer all other means of containment have failed
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Slant Hop
Limit 3 3 [-20, +50] m [-20, +20] m [-10, +120] m 15 m/s 45 deg/s 23 deg/s 20 deg/s 20 deg 0.1 [-30, +120] m [-35, +35] m [-1000, +150] m 20 m/s 1 1 1 [1,2] 0 n/a 2 # Strikes 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 n/a* n/a* n/a* n/a* n/a* n/a 1
HDP
Limit 3 3 [-35, +1116] m [-50, +50] m [-35, +1000] m 27 m/s 45 deg/s 35 deg/s 35 deg/s 20 deg -10.0 [-70, +1166] m [-70, +70] m [-70, +1100] m 32 m/s 1 1 1 [1,2] 0 n/a 1
**SoZ Abort condiJon can be disabled via I-load, if desired. Default is shown.
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Key Concerns
Exposure to vehicle crash, re, high temperatures, cryo temperatures, noise, pinch points, lasers, asphyxiates
Approach
Remove personnel from proximity by enforcing safe distances (range clear) Employ ConJngency Management System (CMS) as well as commanded aborts Use of PPE Team cerJcaJon and training Procedural controls Test rules Enforce safe distances for public Employ ConJngency Management System as well as commanded aborts Employ ConJngency Management System as well as commanded aborts Rigorous re control Pre-declare loss of vehicle is not a mishap. Vehicle and Morpheus equipment hazards are handled as project risks
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Exposure to vehicle crash, widespread vegetaJon re Loss of vehicle during ight or damage during ground operaJons
Security Closures
Security Closures
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PPE is required during cryogenic ows. PPE includes: face shield, goggles, gloves and apron during transfer; safety glasses and gloves for venJng or dump operaJons per procedures Transfer of liquids must include second operator for buddy system Morpheus is leveraging off ESTA experience with cryo handling
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All hazards will be controlled to a Risk Assessment Code (RAC) of 4 or beier (Acceptable with Controls), requiring Branch Chief- level signature
Branch chief level signature means that Project management can accept controls and residual risk.
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Performance Characteriza;on
ATTRIBUTE Stable, controlled ight from takeo through landing Main engine performance Roll control performance Vehicle robustness in ight environment (EMI, vibe, overpressure, thermal, wind gusts) Robustness to propulsion system coupled interacJons (integrated main engine/RCS, thrust, pressure, imbalance, temperature eects) Demonstrated soZ abort capability Margin for meeJng ALHAT trajectory requirements Margin for meeJng ALHAT poinJng stability and control requirements ALHAT performance TT Hop HDP
n/a n/a
n/a n/a
Healthy Known issues or forward work Cant fully characterize unJl we start ying at KSC
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Reliability
ATTRIBUTE Reliable vehicle communicaJons Reliable ight computer Reliable instrumentaJon Mature soZware Reliable propulsion hardware (feed system, EMAs) Reliable roll control hardware Reliable GN&C hardware Reliable main engine Healthy power margin Healthy propellant margin Healthy structural margin Reliable thrust terminaJon system Reliable control center Reliable remote connecJvity for JSC and ALHAT teams to parJcipate TT Hop HDP
Healthy Known issues or forward work Cant fully characterize unJl we start ying at KSC
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Healthy Known issues or forward work Cant fully characterize unJl we start ying at KSC
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MMCC setup Comm &Telemetry and Flight TerminaJon Radio setup Free-Flight Ops simulaJons including range safety simulaJons Finalize camera posiJoning KSC dry-run and wet-run (scheduled for tomorrow) Methane RCS engine tesJng and control system renement HD5 repair and re-test HD4 trajectory shaping ALHAT/Morpheus Nav Jme lag x and tesJng
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JSC Systems Engineering G&N Algorithms ALHAT/Morpheus Sim System Avionics HSI
Develop and mature to TRL6 an autonomous planetary landing GN&C and sensing system for crewed, cargo, and roboPc planetary descent vehicles. The System will be capable of idenPfying and avoiding surface hazards to enable a safe precision landing to within tens of meters of cerPed and designated landing sites anywhere on the planet under any lighPng condiPons.
1.5 3 min
Pitch-up Maneuver
Short pitch-up and throttle-down maneuver
~15 km
Touchdown
~50 m
ALHAT has advanced the state of the art in the use of ash lidar technology for the HDA and HRN funcJons.
Doppler Lidar
ALHAT Doppler lidar provides an order of magnitude higher accuracy than instruments in use for current missions, eecJve for the terminal descent phase of ALHAT operaJon. High-precision, eye-safe laser alJmeter provides three orders of magnitude higher resoluJon than radar alJmetry. Tested successfully for the TRN funcJon.
Laser AlJmeter
Considerable analysis and engineering eort was uJlized to determine sensors, soZware, and techniques required to meet the level 0 requirements
FT4
Sensors On Morpheus
Sensors On Morpheus
All open items are scheduled for compleJon prior to shipping ALHAT Systems to KSC rst week in September No known show stoppers, however, the major lesson learned so far this scal year is that integraJon and tesJng always seems to throw you a curve and you have to react