Tethered Test

7/28/2019 Tethered Test

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MorpheusTetherTestReadinessReview(TRR)MorpheusIntegratedT&VJeremyHart/EG

4/20/11


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TestObjecves TestPlan

Overview ConOps

TestMatrix/Cases TestArcleDescripon/Configuraon Pre-TestVerificaonCriteriaReview Openwork TestSafety TestStopandSuccessCriteria TestSchedule Backup

Agenda

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PrimaryObjecves,Integrateddynamictestoffullvehicle:1. Closed-loop GNC with 3-axis attitude control (hover stability, vertical

translation)!a) Test of tank loading CG management and/or knowledge handoff to GNC!b) Test of throttle up stability !c) Test of hover stability!d) Test of navigation system in dynamic flight!e) Test of complete flight activation and shutdown sequence by AFM!f) Demonstration of robustness to wind and ground prop interaction!g) Roll control including roll control impulse bit!

2. Characterize slosh damping!3. Characterize CG management!4. Long duration engine burn (TT Day 2) and steady state engine temp!5. Wireless FTS end-to-end (TT Day 2+)!

TestObjecFves

3


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Secondary Objectives:!1. GNC !

a) Possible test of soft abort command during hover flight condition!b) Possible test of hard abort command during hover flight condition!

2. Calibration of flight control propellant depletion estimator (TT day 2)

TestObjecFves

4


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PadSetup:Crane,energyabsorber,vehicle,andGSE LOX/LNGFill VehicleHoist5

Openrollvalvesforli[ PadClear Pressurizetoflightpressure Performtethertesng(2X)

Ignion HandovertoGNC Vercaltranslaon(5upto+3) Hover(30seconds) Landattheendoftether

Depressurize Lowerandweightthevehicle Vent/Draintanks

TestPlan-Overview

5


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Posioncrane,vehicle,energyabsorberandGSEatTethertestpad

FillvehiclewithLoxandLCH4,pressurizeto


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TetherTestIniFalSet-up

7

Battery Cart

Helium tube trailer32 feet

100 feet

Bldg 18Control Center

1000 feet

Solenoid 12VPower Supply

APU Power Cable

GHe Disconnect

Power SupplyWiring and

GHe QDLanyard

LNG Trailer

Portable

GHe R-bottle

15 feet

Pressure Panel

15 feet

Lox Dewars and Trailer

Portable

GHe R-bottle

EnergyAbsorber

New Items:-100 ton crane-Energy Absorber-REMOVED straps


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Raisevehicle5viacrane Openrollvalvesduringli[

Installcraneshieldovercranecab EvacuateCryodewarsandbaerycart TransfertofullGHetubeandsetsupply

regulatorto300psig

Clearpadcrewandriggersto>=1000[ Pressurizevehicletoflightpressure(~220

psigtarget)

TestPlan:

PadClearandGHePressurizaFon

8

5

GHe QD

Crane cabShield


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IniateQuickDisconnectofGHEline EngineIgnion HandovertoGNCcontrol

TestPlan:

EngineIgniFon

9

5

Ghe QD

20

3


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Vercaltranslaon,5withupto+3dispersion

Hover(20seconds) TerminalDescent

1m/sdescentrate Landattheendoftether

TestPlan:

VerFcalTranslaFon

10

5

~5


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Landattheendofthetether Someamountofenergyabsorberstroke

distance(x)

Ventvehicleto


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Lowervehicletothepad(ontovehiclescales?)

Vent/drainremainingLNG/LOX Flightsecurecallwhentanksaredrained

and


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irstDayTestMatrixIgniFonTesFng

13

Sequence#

#ofruns

Config/TestVariables

SuccessCriteria

ControlMethod GN&CConfiguraFon Notes TankPressure

#0

GNC

handoff

1 Thrust/weightless

than1

Successful

handoverto

GNC

Nominalstartup

sequence.So[abortto

terminate(before10

seconds)

ClosedLoopGNC 220+/-5psig

#1

Nominal

TetherTest

1 TetherGuidanceI-

loads

Successful

startup,

hover,vercaltranslaon,

shutdown

Nominalstartup

sequence.25second

hoverduraona[ervercaltranslaon.

ClosedLoopGNCTetherGuidI-loads Vehiclewillremainon

tetherbetweentests

220+/-5

psig


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irstDayTestMatrixIgniFonTesFng

14

Sequence#

#ofruns

Config/TestVariables

SuccessCriteria

ControlMethod GN&CConfiguraFon Notes TankPressure

#0

GNC

handoff

1 Thrust/weightless

than1

Successful

handoverto

GNC

Nominalstartup

sequence.So[abortto

terminate

ClosedLoopGNC 220+/-5psig

#1

Nominal

Tether

Test

1 TetherGuidanceI-

loads

Successful

startup,

hover,vercal

translaon,shutdown

Nominalstartup

sequence.20second

hoverduraona[er

vercaltranslaon.

ClosedLoopGNCTetherGuidI-loads Vehiclewillremainon

tether

betweentests

220+/-5

psig

#2

So[

Abort

Test

1 TetherGuidanceI-

loads

Successful

startup,

hover,vercal

translaon,

so[abort

Nominalstartup

sequence.20second

hoverduraona[er

vercaltranslaon.So[

abortat~15secondsof

hover.

ClosedLoopGNCTetherGuidI-loads So[abort,thenhard

abortto

terminate

thrust

220+/-5

psig


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1515RafaelJimnez,(281)244-6681 NASA/JSC-EP4-Propulsion 03/23/11

Morpheus Configuration forTether Fire Test with NEW items

LOX Tanks (X2)

Methane Tanks (X2)

Primary

Structure

Landing Gear

(X4)

Lifting Points (X4)

Tank Support Struts (X8)

Landing Gear

Crushable Pads (X4)

Landing Gear

Accelerometers (X3)

New DFI Box

New Items:- FTS radios and batteries

-Latest FSW-Tether GNC i-loads-APU box h-bridge fix?

All OI and DFI in place


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MorpheusVehicleDI

16

Top deck near avionics

HF triaxial accel (3 HF channels) 20 kHzLF triaxial accel (3 LF channels) 1000 Hz

Microphone (1 HF channel) 20 kHz

Pressure transducer (1 LF channel) 1000

Hz

Thermocouple (1 TC channel) 2.1 Hz

On frame

Microphone (1 HF channel) 20 kHz

Pressure transducer (1 LF channel) 1000 Hz

Thermocouple (1 TC channel) 2.1 Hz

On top of each footpad

4 LF triaxial accels

(12 LF channels) 1000 Hz

FT1 and FT3 (1 LOX & 1 LCH4 tank)

Strain gauges 100 Hz

(4 sets of full bridges each tank)

On frame at top and bottom of each tank

8 LF triaxial accels (24 LF channels) 1000

Hz

On each foot pad

4 load cells (4 LF channels) TBD Hz

Channel Count5 HF channels45 LF channels

30 TC channels8 strain gauge full

bridges

On all four tanks

7 TCs on each tank 2.1 Hz

Items in blue required for LN2 Inert TestingItems in blue and orange required for hot-fire and tethered test

Items in blue, orange, and green required for free flight

Same as HF day 2


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Prop Engineclean-up Gimbalperformanceevaluaon(rateseenduringHotFire?) Vehicledrymassbalanceevaluaon(addballastasneeded) Propellantmanagementplanconfirmtestmatrixcanbecompletedandsim

RiggingPlan Craneposioningandfinaldimensions(craneloadsetto20,000lb),pendulum

moondoesnotallowcontactwithcranecab(Bailey)

Loadtesngofstraps Protecngvehicletopdeckfromslacktether(PVC/bungee)testinb220 MarktheenergyabsorbersoanystrokecausedbyfirstruncanbeseenattheRC

shack Concurrencefromcranesafety(SteveDaniel)

EPS APUboxfix(ribboncablere-wiring,noFSWchangerequired)-tesng Almetersourcevoltagechangeto28Vneedtotestchange

FTShardwire

TetherTestOpenWork

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GuidanceChanges Guidancefixfor20secondmeout(HotFireDay2issue) Guidancefixfornorebootupondouble-acvaon

EMAcalibraon Throle/Thrustdatacalibraoncurves EMAmeasurementsandcalibraoncurves

So[andHardAbortBoundariesundercrane(Values:?) Tesngoftetherrunsinsimulaonwithday-of-testprocedures OponalChanges:

Propnewtemperatureslook-uptable NewhardabortbehaviorforEMAcontrol(yes) Navmovetotablei-loads&commandtochangei-loads(NOinnovday) Makedecisiononlimitchecker(NOinnovday) Propnewloadingsequencemethanefirst(NOinnovday)

TetherTestOpenWorkSWandGNC

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Sloshdamping.VerificaonthatMorpheusprovidesatanksloshdampingraoof>0.25overthefullrangeofliquidlevels.

Overpressureevaluaonis5feetlowenough?Li[-offfromground? Reachsteady-stateonenginetemp(TBDduraonis20secondsok?) FSWTetherDynamicTest.Verifyrequirementsrelatedtoenginetrustand

gimbalactuaonforGNCatudeandposioncontrol. R.RR2.FSW.062;R.RR2.FSW.063;R.RR2.GNC.05;R.RR2.FSW.149

MoonImagery.Verificaonthattheimagerysystemcaptureshi-defmoonimagerystarngwithignionsequenceandendingwithvehicletouchdown

Itemsthatwereinoriginalverificaonplanning: TrajectoryUpdates.VerificaonthatMorpheuswillacceptupdatestotheguidancereferencetrajectoryduringpoweredflight VehicleTurnaround:VerificaonthattheMorpheusvehicleiscapableofre-flight

within2hours

TetherTestVerificaFons

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TestSafety

Phase Commodity Pressure Personnel

Distance

RaFonal

OverPressure

RaFonal

ragmentaFon

LeakCheck GHeorGN2 Lessthan50PSIG 32for10min

0a[er10min

Safe@32

ImprobableRupture

Ducle

NonCredible

ColdFlow LN2Loading

LN2w/GHe

0to25PSIG

Lessthan25PSIG

25to50PSIG

15

0a[erflowstop

32for10min

0a[er10min

Safe@15

ImprobableRupture

Safe@32

ImprobableRupture

Ducle

NonCredible

Ducle

NonCredible

HotFire LOXandLCH4Loading

GHePressLeakCheck

GheFlightPress

PostTest

Fillat25PSIGTank

Lessthan25PSIG

Pressto45PSIG

Pressto235PSIG

Depressto50PSIG

15

0a[erflowstop

32for10min

0a[er10min

1000

1000to0

Safe@15

ImprobableRupture

Safe@32

ImprobableRupture

Safe@1000

ImprobableRupture

Ducle

NonCredible

Ducle

NonCredible

Safe@1000

NonCredible

Note

Improbable Rupture due to quiescent linear strain in the membraneNon Credible due to unlikely rupture and unlikely shrapnel.


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Operation PPE Notes

Crane/forklift lifting ops Hard hat, steel toe shoes,

safety glasses

PPE needed when working

inside lifting zone

Vehicle prep (pre-cryo

loading)

Safety glasses, work gloves

(recommended)

All vehicles parked behind

helium trailer (150 foot

minimum distance) to allow

room for lift/tow ops.

Cryo transfer hose

hookup & valve operation

Goggles, face shield, cryo

apron and gauntlet gloves,

cuffless trousers, sturdy shoes

Establish 15 foot safe

distance prior to flow

Post-cryo fill vehicle ops,

tank pressure


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StopCriteria Anyunexpectedvehiclemoonparcularlylaterallytowardscrane Observedengineerosion(yellowflash) EngineredlinelimitsRobmonitoringandwillmakecall Lossofcertaininstrumentaonsensorsenginewillnotlightforcertainsensor

failures

Lossofenginevideofeed

TestStopCriteria

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SuccessCriteria Stableengineignion HandovertoGNCFSW Stablevercaltranslaon Stablehoverwithacceptablegimbalposion Acceptableenginewear Steady-Stateenginetemperaturereached Acceptablesloshdamping(dampingraoof>0.25) Subsystemleadconcurrence

Allsubsystemleadsaresasfiedthattheirsubsystemisreadyfortetheredtesng FTShasbeenverifiedend-to-endduringanenginefiring Allhotfiremandatoryverificaonshavebeencompleted

SuccessCriteria

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Tether#1scheduledfor4/25/2011 Tether#2scheduledfor4/27/2011

Addionalitemsfortest:WirelessFTS,Lateraltranslaon

TestSchedule

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BACKUP

26


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Safety-VCRangeDefiniFon1000Buffer

27*Scale, 1.29 = 640

b18

b14

**Center,4.56, 4.22

1500

Tower

Tether

Landing

Launch

Saturn Lane

1000

1000

1000

VFC Range Boundary


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VCLaunchPadDistancestoLandmarks

28*Scale, 1.29 = 640

b18

b14

**Center,4.56, 4.22

2000

2040

1400

2080

2160

1500

1000

Tower

Tether

Landing

Launch

Saturn Lane


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FTSverifyend-to-endperformance(sllopen) Prop

CGmanagement.VerificaonthattheMorpheusshallmaintainaCGrangeperrequirementthroughoutalloperaons.(balancetesng)

Gimbalenvelope(Hot-fireday2)VerificaonthatMorpheusmeetsperformancerequirementswhileoperangwithintheenginegimbalenvelope.

Verificaonthatthemainengineiscapableofa5degreepersecondangularrate Verificaonthatthegimbalpointisbelowthevehiclecenterofmass

Structures(seriesoftestatandaboveflightloads) EnergyAbsorber.Verificaonthatthegroundsystemshallprovideanenergy

absorbertoaenuatetetheredloadsatJSC

TetherTest

VerificaFonEntranceCriteria

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GNC EMAperformancecharacterizaon.CalibrateencodersonTVCandthrole

actuatorsRunbandwidthresponsetesngonTVCandthroleactuators

Validate/updatesimulaonEMAmodelsValidateflightperformancewithmargin

insimulaon

GNCfunconaltesng,Nominalandoff-nominalperformanceevaluaon Status?

FSW HASTDynamicsimulaon.VerifyFSWrequirementsassociatedwithflight

corridorcondionsandGNCatudeperformanceboundaries.

HASTOff-nominaldynamicsimulaon.VerifyFSWrequirementsassociatedwithabortcondions.

Status?

TetherTest

VerificaFonEntranceCriteria(contd)

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Documents

Tethered Test