RUAG Reusable Payload Fairing 32nd National Space Symposium Colorado Springs, US April 11-14, 2016 Andreas Wiesendanger Program Manager RUAG Space

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Overview  Introduction  PLF Analyses  CFD Simulation  Fluid-Structure Interaction

 PLF Recovery System Concept  Mid-Air Recovery  In-Water Recovery

 Outlook  Build-up of demonstrator  In-flight demonstration

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Reusable Payload Fairing Introduction  Increased competitive environment is driving to drastic cost reductions.  Recovery and reusability of PLF could support reduction of recurring costs.  PLF retrieval system is also a pathfinder for extended recovery and reusability of high value LV elements.  Advantages of Parachute Recovery System: relatively low-mass and passive operation.  Demonstrate feasibility  In-flight demonstration

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Reusable Payload Fairing Introduction

Recovery system compartment

Drogue / Stabilizing parachute

 Recovery system Mid-Air Recovery In-Water Recovery  Payload Fairing Approx 1 ton per half-shell Flexible structure Composite sandwich

Extraction device / Mortar system

Main parachute

Floating device compartment

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Reusable Payload Fairing Introduction  Main topics investigated 

Aerodynamic stability of the PLF during re-entry (CFD analyses)

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Re-entry loads on the PLF and structural integrity

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Recovery concept / systems 

Mid-air recovery

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In water recovery

PLF flight trajectory

Ballistic phase

Stabilized fall

Aero / Thermal loads

Low-speed fall

300-1’000 km

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Recovery: MAR On-Water

PLF Analyses Results CFD Simulation Trajectory Simulation and CFD Analyses  Fully coupled with CFD solver to take into account aerodynamic damping.  Covering sub- and supersonic flight conditions and different PLF attitudes.

Subsonic regime  Non-streamlined geometrical shapes in low-speed regime present a special challenge for CFD numerical simulation.  ‘Lattice Boltzmann Method’ (LBM) selected as best approach in terms of CFD simulation for low-speed.

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Supersonic regime  Supersonic load cases calculated with normal ‘Reynolds Averaged Navier-Stokes’ (RANS) method.

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PLF Analyses Results CFD Simulation: Sensitivity study  Ideal PLF (homogeneous mass distribution) is aerodynamically stable whereas a Real PLF is not

Ideal PLF

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Real PLF

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PLF Analyses Results CFD Simulation: Supersonic

Case 3

Case 2 Case 1

Pressure Low

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Ambient

Reynolds Averaged Navier-Stokes (RANS) High

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PLF Analyses Results CFD Simulation: Subsonic

Case 1

Case 2

Case 3

Lattice Boltzmann Method (LBM) 9│RUAG Space

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PLF Analyses Results Case 3 - Outer pressure

Fluid-Structure Interaction Case 2 -from Outer pressure  Pressure distributions CFD analyses implemented in FE model.

Case Case 3 2 -- Inner Inner pressure pressure

 Predicted max. dynamic pressure case around 56 km altitude.  Different load cases and PLF attitudes analyzed.

Case 2 - Delta pressure

* Represents qmax condition

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PLF Recovery System Concept Baseline  Reference architecture per PLF half-shell:  Ballistic drogue parachute  Main parachute (ballistic / parafoil)  MAR or in-water recovery  Floating device  Drogue system:  stabilization purposes  Avoid critical PLF attitudes in air stream  Facilitate deployment of main parachute  Main parachute: provides the necessary aerodynamic drag in order to slow the PLF to acceptable descent rates  Floating devices: may be incorporated to allow landing in water and subsequent recovery

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PLF Recovery System Concept Mid-Air Recovery Drogue Parachute  Assembly Mass: approx 4.5kg (10lbs)

 Canopy 9.85ft Do Conical Ribbon Primary materials: Nylon, Kevlar structure 12 gores and 22 ribbons

Drogue Canopy & Lines (model reference only)

 Suspension lines and riser Primary materials: Kevlar Suspension line length ratio: 1.15

 Deployment Bag Primary materials: Gentex, Kevlar structure Protects from hot gases and allows for controlled deployment

Drogue Deployment Bag

 Mortar Assembly o o o o o

Provides energy to deploy package (expose canopy skirt) Pyrotechnic .vs. pneumatic operation options Derived from Shuttle program: 100+ operations within 7.4” mortar class and similar pack weights Threaded components with dual locking features Eroding orifice technology to reduce reaction loads: 35.5kN 44.4 kN (8-10 kip)

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Mortar Assembly

PLF Recovery System Concept Mid-Air Recovery MAR Parafoil Requirements  Low descent-rate to maximize time for Helicopter/Parafoil interception and MAR.  Forward-speed above helicopter translation and aero-grapple maneuvering speed.  High altitude deployment capability (~11km).  Effective reefing system for reduced mass.  High density packing. High reliability. Parafoil Sizing  Descent-rate o Low descent-rate: increases time for Helicopter to intercept Parafoil. o Wing loading: in excess of 2:1 results in high descent-rate and steering sensitivity.  Forward-speed o Wing loading: of less than 1:1 reduces Parafoil forward-speed below helicopter translation and aero-grapple maneuvering speed.

Preliminary Parafoil Design (Estimates) Description Mass T- half shell

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Wing Recovery Weight Loading kg lb/ft2 1000 1.6

Parafoil Average Area Descent Rate ft2 fps 1587 20

Parafoil Weight lb kg 85 38

Pack Density lb/ft3 30

Pack Volume at 30 lb/ft3 Span ft3 ft 2.82 50.40

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Chord ft 18.33

Aspect Ratio 2.75:1

PLF Recovery System Concept Mid-Air Recovery Drogue to Parafoil Hand-off  High altitude Parafoil opening desired to increase time available for MAR operations.  PLF flight stability required for reliable Parafoil deployment.  Parafoil deployment options: via Pilot chute, Drogue or deployment line attached to the stabilization drogue.  Standard slider reefing system for deployment.  PLF strength capability defines max allowed Parafoil opening force.  High drag payload under Parafoil reduces glide-path performance.  Controlled payload orientation for high speed ferry may be required.

PLF Tracking  Range Tracking o o

VHF aircraft band radio communications with helicopter Visual acquisition (crew members)

 ADS-B Out Transmitter on the payload

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PLF Recovery System Concept Mid-Air Recovery 3G MAR with efficient load transfer  Capture line routed over front (nose) of Parafoil.  Helicopter positioned over Parafoil/payload.  Load transfer releases Parafoil from capture line, followed by Parafoil jettison (radio control from helicopter).  Aero-grapple traps capture line during Helicopter fly over.  Reduce helicopter sink-rate creating vertical separation until stop contacts grapple  Continued vertical separation pulls-up slider, collapsing Parafoil  Allows high-speed longdistance ferry (may require payload drogue). Simplifies payload set-down.  Does not require wrangling the Parafoil after payload set-down

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Capture line

PLF Recovery System Concept Mid-Air Recovery

Stern Integral Heli-Pad

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Bow Mount Heli-Pad Installation

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PLF Recovery System Concept In-Water Recovery Alternative Recovery Option

110 km 361 kft

1

83 km 271 kft

55 km 180 kft

28 km 90 kft

0

2 3-4

1. PLF half-shells separated from Launch Vehicle at 110 km. 2. Drogue mortar deployed at certain altitude inflates and stabilizes PLF half. 3. Drogue separated from PLF with sequence cutter; releases and extracts Main Parachute assembly via static line attachment at specific altitude. 4. Main parachute inflates and controls PLF final descent. 5. Floating devices inflated/released prior to landing in-water. 6. Beacon initiated for recovery operations.

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PLF Recovery System Concept Outlook Phase 1 (2015-2016)  Concept study o o

Feasibility studies: aerodynamic, technologies identification, concept definition Sub-system identification and preliminary definition

Phase 2 (2016)  PLF Impact study o o o

Detailed impact study on PLF (mechanical, dynamic, kinematics, …) Mass-breakdown and CoG Performance of sub-systems development tests

Phase 3 (2017-2018)  In-flight demonstration o o o o o

Selection of demonstration objectives/mission Definition of test article Procurements Realization of in-flight demonstration Evaluation of test data

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© RUAG Schweiz AG 2016. This document shall not be used for other purposes than those for which it was established. No unauthorised distribution, dissemination or disclosure. RUAG PROPRIETARY INFORMATION