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National Aeronautics and Space Administration

www.nasa.gov

Ares I-X INDUSTRY DAY Ares I-X INDUSTRY DAY

Scott Graham

William Foster

Monica Hoffmann

Timothy Gaydos

14 November 2007

Scott Graham

William Foster

Monica Hoffmann

Timothy Gaydos

14 November 2007

2National Aeronautics and Space Administration

AGENDA

8AM Badging and Manufacturing Facilities Tour Sign Up

8:30AM Welcome

8:35AM Ares Program Overview

8:45 AM Ares 1-X Program Overview

9AM Ares1-X Statement of Work

9:50AM Quality Assurance Plan

10AM Open Forum Questions and Answers

10:30AM Tours of Ares1-X Manufacturing Facilities

11:30AM- 1PM – LUNCH - Break Independently for Lunch

1PM Continue One on One Private Conversations as needed

(20 minutes each)


www.nasa.govwww.nasa.gov

Ares Program OverviewAres Program Overview

Scott Graham

November 14, 2007

Scott Graham

November 14, 2007


The Vision for Space Exploration

Complete the International Space Station.Complete the International Space Station.

Safely fly the Space Shuttle until 2010.Safely fly the Space Shuttle until 2010.

Develop and fly the Crew Exploration Vehicle no later than 2014 (goal of 2012).Develop and fly the Crew Exploration Vehicle no later than 2014 (goal of 2012).

Return to the Moon no later than 2020.Return to the Moon no later than 2020.

Extend human presence across the solar system and beyond.Extend human presence across the solar system and beyond.

Implement a sustained and affordable human and robotic program.Implement a sustained and affordable human and robotic program.

Develop supporting innovative technologies, knowledge, and infrastructures.Develop supporting innovative technologies, knowledge, and infrastructures.

Promote international and commercial participation in exploration.Promote international and commercial participation in exploration.

Complete the International Space Station.Complete the International Space Station.

Safely fly the Space Shuttle until 2010.Safely fly the Space Shuttle until 2010.

Develop and fly the Crew Exploration Vehicle no later than 2014 (goal of 2012).Develop and fly the Crew Exploration Vehicle no later than 2014 (goal of 2012).

Return to the Moon no later than 2020.Return to the Moon no later than 2020.

Extend human presence across the solar system and beyond.Extend human presence across the solar system and beyond.

Implement a sustained and affordable human and robotic program.Implement a sustained and affordable human and robotic program.

Develop supporting innovative technologies, knowledge, and infrastructures.Develop supporting innovative technologies, knowledge, and infrastructures.

Promote international and commercial participation in exploration.Promote international and commercial participation in exploration.

“The next steps in returning to the Moon and moving onward to Mars, the near-Earth asteroids, and beyond, are crucial in deciding the course of future space exploration. We must understand that these steps are incremental, cumulative, and – incredibly powerful in their ultimate effect.”

– NASA Administrator Michael Griffin

October 24, 2006


Ares ICrew Launch

Vehicle

Earth Departure Stage

OrionCrew Exploration

Vehicle

LunarLander

Our Exploration Fleet

ELO Ambassador Briefing – 5

Ares VCargo Launch

Vehicle


Building on a Foundation of Proven Technologies- Launch Vehicle Comparisons -

Crew

Lander

S–IVB(1 J–2 engine)240k lb LOx/LH2

S–II(5 J–2 engines)1M lb LOx/LH2

S–IC(5 F–1 engines)3.9M lb LOx/RP

LunarLander

Earth DepartureStage (EDS) (1 J–2X)499k lb LOx/LH2

Core Stage(5 RS–68 Engines)3.1M lb LOx/LH2

Upper Stage(1 J–2X)

280k lb LOx/LH2

5-Segment Reusable Solid Rocket Booster (RSRB)

Space Shuttle Ares I Ares V Saturn V

Two 5-SegmentRSRBs

Orion CEV


Ares I-X: The First Test Flight (April 2009)

Thrust < 40K lbsSeparation begins

Launch BoosterRecovery

Upper Stageand CEV/LAS

Disposal

Sep + 20 secsChute deployment

Sep + 10 secsFrustum/Interstage separation

USS/CM/LAS data downlink


www.nasa.gov

Ares I-X Upper StageSimulator Overview

Ares I-X Upper StageSimulator Overview

William Foster

Industry DayNovember 14, 2007

William Foster

Industry DayNovember 14, 2007


Purpose & Content

Purpose: Introduce the Ares I-X Flight Test

Project and GRC’s Upper Stage Simulator (USS) Integrated Product Team (IPT).

Content: USS IPT Organization Ares I-X Flight Test Overview USS Top Level Requirements Design Concept Operations Concept


Ares I-X Mission Management Office (MMO)

Ares I-X Mission Management Office (MMO)

Chief Engineers Chief Engineers Safety & Mission Assurance (S&MA)Safety & Mission

Assurance (S&MA)

GroundSystems

(GS)

GroundSystems

(GS)

Roll Control System (RoCS)

Roll Control System (RoCS)

First StageFirst Stage

Upper StageSimulator

(USS)

Upper StageSimulator

(USS)

AvionicsAvionics CM/LASSimulatorCM/LAS

Simulator

Systems Engineering & Integration (SE&I)

Systems Engineering & Integration (SE&I)

GroundOperations

(GO)

GroundOperations

(GO)

Ares I-X Organization

Integrated Product Teams (IPTs)

Dan Mullane/MSFCDan Mullane/MSFCJoe Brunty/MSFCJoe Brunty/MSFC

Steve Sullivan/KSCSteve Sullivan/KSC

Bob EssMission Manager

Bob EssMission Manager

Steve DavisDeputy, MSFC

Steve DavisDeputy, MSFC

Carol ScottDeputy, KSC

Carol ScottDeputy, KSC

Marshall SmithSE&I Chief

Marshall SmithSE&I Chief

K. RobinsonProject IntegrationK. Robinson

Project Integration

JSC/TBDBudget Analyst

JSC/TBDBudget Analyst

Support StaffSupport Staff

M. Smith/LaRCChief

M. Smith/LaRCChief

K. Detweiler/LaRCLSE

K. Detweiler/LaRCLSE

W. Pennington/LaRCDeputy Chief

W. Pennington/LaRCDeputy Chief

S. Richards/MSFCDeputy LSE

S. Richards/MSFCDeputy LSE

Scott Thurston/KSCScott Thurston/KSC

Jon Cowart/KSCJon Cowart/KSC

Chris Calfee/MSFCChris Calfee/MSFC

Vince Bilardo/GRCVince Bilardo/GRC

Kevin Flynn/MSFCKevin Flynn/MSFC

Ron Unger/MSFCRon Unger/MSFC

Brian Beaton/LaRCBrian Beaton/LaRC


B. Frankenfield

R. Tornabene, IPT Lead C. Ensworth

A. Baez, EPSJ. Thomas, DFI

G. Hunter, Sensors

A. Narvaez-Legeza, Lead Engr.S. Numbers, PA Lead

Kurt Hack, IDAT. Krivanek, M. McNelis, D.K. Le,

J. Cruz / IV&V

Analyst: T. HalsteadRAMO: C. Stofka

Chief Engineer: C. CunninghamIntegrated Upper Stage: tbd

Safety & Mission Assurance (S&MA)

J. Rusick

Launch Systems Projects Office Glenn Research Center

Program Planning & Control

Manager: R. Speth

Project Control Specialist: Vacant

Chief: S. GrahamDeputy Chief: J. Koudelka

MSA: J. Van HornAdmin Support: C Schilens

Matrix

Direct

Upper Stage

Manager: D. Hoffman

Upper Stage Engine

Manager: C. Meyer

Deputy: J. Rybak

Vehicle Integration

Lead: G. Sadler

Thrust Vector Control

Lead: D. Frate

Deputy: N. Pham

Structures & Thermal

Lead: C. TolbertAvionics

Lead: A. Jankovsky

Test Vehicle Integration Deputy: P. Bartolotta

CEV SA/SM Test Article Lead: F. Elliott

Ares I-1 GRC Elements

Manager: V. BilardoUS Test Article Lead: W. Foster

Interstage Element Lead: M. HoffmannGround Processing Lead: J. Lekan

Struct, Envir & Vibration Test Lead: M. Tuma

Flight & Integrated Test: MSFC

- Test Vehicle Integration -LaRC

12

WBS .10IPT Management

Vince BilardoBill Foster

Jack LekanMonica Hoffman

WBS .20SE&ITeam

Tom Doehne

WBS .30S&MATeam

Jeff Rusick

WBS .40.01Struct/Mech

TeamJim Hunter

WBS .40.02Design/Drawings

TeamCarl Blaser

WBS .40.06Mfg/Weld Eng

TeamKarl Bergquist

WBS .40.03Struct Dynamics

TeamMark McNelis

WBS .42.01Manufacturing

TeamPeter Tschen

WBS .42.02Instrumentation

TeamGreg Blank

WBS .40.04Fluid/Thermal

TeamGeorge Harpster

WBS .10Config MgmtKaren Hughes

WBS .10Business Mgmt

Tracy KammDavid WolfeKathy Kelley

WBS .50Ground Systems

Jack Lekan

WBS .80KSC Processing

TeamJack Lekan

WBS .40.05Avionics

Team Steve Mainger

WBS .70.01Test & Verif

TeamBill Thompson

WBS .41Interstage DesignMonica Hoffman

WBS .43Separation

SystemTom VanNuyen

WBS .60Logistics

&TransportationAlan Kane / Sue Kraus

WBS .10Segment Lead

EngineersUS-2/3 Jack Dalzell

US-4/5 TBD

ITAChief EngineersAda Narvaez-

LegezaDamian Ludwiczak

WBS .70.02Inspection Team

George Saad

AIX USS IPT Organization

08 Aug 07


Ares I-1 Flight Test Profile

Thrust < 40K lbsSeparation begins

Launch BoosterRecovery

Upper Stageand CEV/LAS

Disposal

Sep + 20 secsChute deployment

Sep + 10 secsFrustum/Interstage separation

USS/CM/LAS data downlink


Flight Test Plan USS Constraints

Item USS Requirements and Constraints

1 USS shall be designed to allow all assembly and checkout with limited, internal access from Interstage area; No other access above Interstage will be provided.

2 Development Flight Instrumentation (DFI) will be installed and tested at GRC prior to shipping. Final integrated instrumentation checks will be performed at KSC with EGSE provided by FTV.

3 USS shall not be recovered and will free fall into the ocean.

4 USS shall simulate the Ares I Upper Stage OML and will have sufficient mass property (total mass, CG, and inertias) characteristics to meet primary objectives.

5 USS Flight Termination System shall not be required.

6 Unique GSE for USS transportation, assembly, and test will be fabricated at GRC.

7 Processing of USS hardware will be in accordance with Appendix E, Problem Reporting and Work Control Plan.


USS Architecture

USS Hardware Interstage (IS) Simulator

Internal Access Service Panel Integration of other Elements:

Roll Control System (RoCS) Separation event diagnostics and

instrumentation system Upper Stage (US) Simulator Spacecraft Adapter (SA) Simulator Service Module (SM) Simulator Integration of avionics/DFI along the

length of the USS

USS External Interfaces First Stage (FS) RoCS Crew Module/Launch Abort System

(CM/LAS) Avionics Ground Systems (GS)

Simulated fifth segment

CM/LASSimulator

Four-segment motor

Upper Stage Simulator

FS

Frustum

Avionics(internal)

Forward Skirts

Spacecraft Adapter and Service Module

Simulators

Upper Stage

RoCSUSS to RoCS Interface

USS to CM\LAS Interface

USS to FS Interface


USS Internal Access Concept [USS-012, -013, -023, -024, -095, -103, -108, -110]

Provides human access from the FS Frustum to the CM/LAS via the Upper Stage Access Arm at the KSC launch pad 39B and VAB platform E scaffolding Door in the IS-1 Internal access platforms and ladders Provides ECS ductwork to maintain a safe

work temp., air flow and controlled humidity

Allows for installation and assembly of hardware

Internal access door

Access platforms with railings

Ballast platform

Ladders are staggered 90 degrees between platforms


Typical Segment

Typical Stack

USS ECS & Ascent Venting[USS-108, -023, -024, & USS-014]

US-1

8” Ascent VentsBackflow device

not shown

14” ECS DuctAvionics ductingnot shown

8” Ascent VentsBackflow device

not shown


USS Adjustable Mass Ballast [USS-017, -075, -123]

USS is a mass simulator Provides majority of adjustable ballast

for FTV’s mass, CG, moment of inertia distribution

2” Ballast Plates are ~ 7,500 lbs each US-1 ~ 17 plates +/- 2 plates US-7 ~ 5 plates +/- 2 plates Total adjustable ballast ~ TBD lbs

Lower adjustable ballast (US–1)

Upper adjustable ballast (US–7)


DFI/OFI in USS[USS-057]

SM

SA

US-7

US-6

US-5

US-4

US-3

IS-2,

IS-1

US-2

US-1

Types of DFI Sensors:Calorimeter Medtherm 20850

Pressure Transducer Kulite XTL-190

Thermocouple Type K

Strain Gage (Uniaxial) Vishay TBD or Equal

Strain Gage (Triaxial) Vishay TBD or Equal

Gas Temperature Probe Medtherm 10561K

Accelerometer (LF) PCB 3741D4HB

Accelerometer (HF) Endevco 7251

Accelerometer (Shock) PCB 350C31

Video Cameras TBD

DFI Avionics Boxes:MDAU (Master Data Acquisition Unit) RDAU (Remote Data Acquisition Unit)Honeywell SIGI (Space Integrated GPS/INS)Systron-Donner MotionPaks (Qty = 2)

OFI Avionics Boxes:FTINU – Fault Tolerant Inertial Navigation UnitRRGU – Redundant Rate Gyro Unit

4 – Strain Gauges;12 – Pressure Transducers

4 – Strain Gauges; 4 – Pressure Transducers

2 – Pressure Transducers

1 – FTINU; 6 – Pressure Transducers; 2 – Calorimeters; 2 – Thermocouples;

3 – Accelerometers (Shock)

2 – Calorimeter; 2 – Thermocouples;8 – Pressure Transducers; 4 – Strain Gauges

1 – RRGU; 2- MDAUs 1 – Video Camera; 1 – SIGI ; 11 – Pressure Transducers; 1 – Calorimeter; 1 – Thermocouple; 3 – Accelerometers (HF)

3 – Video Cameras; 28 – Pressure Transducers; 13 – Calorimeters; 18 – Thermocouples;11 – Accelerometers (LF); 12 – Triaxial Strain Gauges; 3 – Accelerometers (Shock)

1 – Calorimeter; 31 – Pressure Transducers;1 – Thermocouple; 3 – Accelerometers (HF); 8 – Accelerometers (LF); 8 – Strain Gauges

18 – Pressure Transducers; 10 – Strain Gauges; 8 – Accelerometer (HF); 4 – Triaxial Strain Gauges; 1 – Microphone

NONE

NOTE: Under revision based on the DFINOTE: Under revision based on the DFIList Version 3.05List Version 3.05


US-6 Common Segment Description

US-6 Common Segment• Design is identical to CDR Charge 1 Segments (US-2,3,4,5)• Steel Grade A70, ½” thick skin, 18’ dia.• Avionics located in segment: Ext. Video Camera (1)

US-6 -- Primary Structure: 13,599.81

Walkway: 3,821.00Platform Hangers: 122.24

OML System Tunnel: 129.22Lifting Lug (4): 151.04

Top Ladder (2): 551.00Bottom Ladder (2): 66.93

Up Alignment Tang (4): 50.52Down Alignment Tang (4): 42.20

ECS Duct: 123.40Sub Total: 18,653.20

ECS


US-7 Ballast Segment - Description

US-7 Ballast Segment•Provides adjustable ballast for FTV’s mass, CG, moment of inertia distribution• 2” Ballast Plates are ~ 7,500 lbs each• US-7 ~ 5 plates (37,677 lbs) +/- 2 plates : • Avionics located in US-7 includes: RRGU (1), MDAUs (2) , Ext. Video Camera (1)

US-7- Ballast Segment Mass PropertiesUS-7- Ballast Segment Mass PropertiesPrimary Structure: 13,662.00Ballast Support Structure: 28,295.90Ballast Plates (5): 37,677.00Ballast Fasteners: 431.26 Super Lifting Lug (4): 1,469.36Top Ladder (2): 593.84Bottom Ladder (2): 61.64Up Alignment Tang (4): 63.81Down Alignment Tang (4): 37.55 External Flange Ring (1): 601.45 External Flange Ring (1): 450.63OML UHF Antenna (2): 100.76OML Camera (2): 142.80ECS Duct: 131.00Sub Total: 83,719.81

US-7- Ballast Segment Mass PropertiesUS-7- Ballast Segment Mass PropertiesPrimary Structure: 13,662.00Ballast Support Structure: 28,295.90Ballast Plates (5): 37,677.00Ballast Fasteners: 431.26 Super Lifting Lug (4): 1,469.36Top Ladder (2): 593.84Bottom Ladder (2): 61.64Up Alignment Tang (4): 63.81Down Alignment Tang (4): 37.55 External Flange Ring (1): 601.45 External Flange Ring (1): 450.63OML UHF Antenna (2): 100.76OML Camera (2): 142.80ECS Duct: 131.00Sub Total: 83,719.81

ECSBolt OnLifting Lug

Ballast CanAssembly

Platform


Spacecraft Adapter Segment Description

Spacecraft Adapter Segment

• Conical Shape Segment-Provides the diameter reduction transition from 18 ft. (216.5”) to 16.5 ft (198 “). • Steel Grade A70, ½” thick skin• Provides similar internal access, ECS design as common segments

Spacecraft Adapter Mass Properties

Primary Structure: 13,012.76 Walkway: 3,145.11Platform Hangers: 122.24Lifting Lug (4): 127.44Up Alignment Tang (4): 50.52Down Alignment Tang: 42.20ECS Duct: 130.98 Sub Total: 16,631.26

Spacecraft Adapter Mass Properties

Primary Structure: 13,012.76 Walkway: 3,145.11Platform Hangers: 122.24Lifting Lug (4): 127.44Up Alignment Tang (4): 50.52Down Alignment Tang: 42.20ECS Duct: 130.98 Sub Total: 16,631.26

Bolt OnLifting Lug

ECSInternal Access


Service Module Segment Description

Service Module Segment•SM Simulator connects to the CM Separation Ring Simulator.•NASA LaRC is responsible for the CM/LAS simulator. •Design similar to common segment; except reduced diameter from 18 ft. (216.5”) to 16.5 ft (198 “)• Provides Internal Access to allow access to CM instrumentation.• Segment interfaces with CM/LAS. This interface includes mechanical bolting of the structural flanges, avionics and environmental interfaces.• Segment Upper Flange is machined to meet the flatness requirements for CM/LAS interface.

Service Module Mass Properties Primary Structure: 11,259.76Walkway: 3,048.54OML Thruster 2 Pack (2): 330.44OML Thruster 6 Pack (2): 684.92Up Alignment Tang (4): 50.52Down Alignment Tang (4): 42.20Lifting Lug (4): 127.44ECS: 41.92Sub Total: 15,585.75

Service Module Mass Properties Primary Structure: 11,259.76Walkway: 3,048.54OML Thruster 2 Pack (2): 330.44OML Thruster 6 Pack (2): 684.92Up Alignment Tang (4): 50.52Down Alignment Tang (4): 42.20Lifting Lug (4): 127.44ECS: 41.92Sub Total: 15,585.75

Internal Access

Bolt OnLifting Lugs

GussetsECS Flange I/F

With CM/LAS


Interstage 1 Segment

Internal Access Entry Services USS and CM/LAS ECS services 1st stage entry

RoCS interface

Interface to 1st Stage

Last segment to be built


USS Element Concept of Operations Overview

-USS Segments to be transported On the Delta Mariner Vessel


USS IPT Concept of OperationsProcessing Flow


USS IPT Concept of Operations Super Segments at GRC


USS IPT Concept of Operations Super Segments at KSC


USS Element Concept of Operations FlowPost Manufacturing at GRC

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Documents

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x manufacturing facilities

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ares program overview8

ares1x statement of

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