Hypersonic Morphing for

a Cabin Escape System

HYPersonic MOrphing for a Cabin Escape System

Authors: D.Bonetti1, M.Sippel2, G.Gambacciani3, E.Laroche4, M.Kerr1, C.Vallucchi2,

F.Fossati3, F.Sourgen4

Presenter: D.Bonetti (project coordinator)1

1 DEIMOS Space S.L.U., Spain2 DLR, Germany3 Aviospace S.r.l., Italy4 ONERA, France

HYPMOCES Concept

Motivation

Technological Objectives

Project approach

Technological solutions

• System design

• Mission Analysis and GNC

• Aerothermodynamics

• Structure, mechanisms and materials

Impact

Conclusions

Contents

The main goal of HYPMOCES is to investigate and develop the technologies in the area of control, structures, aerothermodynamics, mission and system required to enable the use of morphing in escape systems for hypersonic transport aircrafts.

The HYPMOCES project addresses multiple key technological areas through Concurrent Engineering and a Multi-disciplinary Design Optimization (MDO) process to enable the use of morphing in hypersonic escape systems.

Morphing as the technological solution to balance:

• Constraints for the integration within the mother aircraft (compactness)

• Adaptability to the unpredicted and environment

• Multi-phase nature of the mission

HYPMOCES Concept: Introduction

Future hypersonic transportation will

require a passenger escape system

to reach the desired safety levels

• High energy flight

• Systems reliability

(mainly propulsion)

Cabin Escape Systems have been proposed and implemented with

different levels of success in aeronautics and space.

Motivation

Subsonic Supersonic Military Space

Within EU FP7 project FAST20XX

(coordinated by ESA, participated

by DEIMOS, ONERA, DLR and

others), the CES was addressed

for the SpaceLiner mission.

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[k

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Mach Number [-]

SpaceLiner Nominal Trajectory

Full Configuration Ascent

Orbiter Ascent

Orbiter Descent

Hypersonic Regime

Booster

Separation Orbiter

MECO

Motivation: Hypersonic Flight, SpaceLiner CES

orbiter stage

booster stage

passenger cabin

LOX-tank orbiter

LH2-tank orbiter

LOX-tank booster

LH2-tank booster

SpaceLiner (1)

SpaceLiner 2

SpaceLiner 3

SpaceLiner 4

SpaceLiner 5

SpaceLiner 6

SpaceLiner 7

SpaceLiner 7-100

2005

2006

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2008

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2010

2011

2012

SpaceLiner (1)

SpaceLiner 2

SpaceLiner 5

(LH2/RP1)

SpaceLiner 4

SpaceLiner 3

SpaceLiner 7

SpaceLiner 6

(Single Stage)

2005

2006

2007

2008

2009

2010

2011

2012configuration

trade-offs

SpaceLiner (1)

SpaceLiner 2

SpaceLiner 5

(LH2/RP1)

SpaceLiner 4

SpaceLiner 3

SpaceLiner 7

SpaceLiner 6

(Single Stage)

2005

2006

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2009

2010

2011

2012configuration

trade-offs

LOX/RP1

SpaceLiner 5

(LOX/RP1)

Mass: 38 t

Length: 17 m

Morphing is the adaptation of a system to a changing environment

Not necessarily associated with external shape changes

Widely used in aeronautics (subsonic – supersonic), still pioneering in space

and in suborbital flights

Motivation: Morphing

Credits: S.Barbarino

HIAD - NASA

CLIPPER – EU/Russia

SS2 – Virgin Galactic’s

1. System: efficient integration (mass, power, volume)

• Morphing within the escape system

• Escape system within mother aircraft

• System concept

2. Mission and GNC approaches for morphing

• Real time adaptation & reconfiguration of the GNC

– Adaptive Guidance

– LFT/LPV/multimodal control

• Estimation techniques for adaptation / reconfiguration

3. Innovative structural and material solutions:

• Advanced materials, actuators and mechanism and

structural layout

– Ceramic hinges for areas with high thermal load

– Coating protecting lightweight structures from high flux

– Deformable TPS and structures

4. Aerothermodynamics:

• Numerical test bench to support concepts trade-offs

• Micro aerothermodynamics aspects (local gaps, steps)

• Transient effects

• Boundary layer transitions

Technological objectives on multiple areas

Project Manager/

Systems Engineer

Sequential Design (subtask view)

Centralised Design (project view)

Concurrent Engineering Process

“everyone with everyone”

Power

AOCS

Configuration

Thermal

Configuration Power

AOCSThermal

Conventional Design Process

Configuration ThermalPower

iteration

Project Manager/

Systems Engineer

Highly coupled optimization process:

Multi-Disciplinary Design approach

The design from a system level point of view deals with the integration of each subsystem in the most efficient way considering related mass, power required and volume available.

System concept of a hypersonic passengers transportation system

need for a rescue capsule

morphing surfaces within the cabin escape system to enhance vehicle in-flight performance and adaptation to a changing environment.

• Integration of specific hypersonic morphing system solutions adopted (Inflatable / Deployable) within the rescue capsule and integration of the rescue capsule within the SpaceLiner

• Mass, Power and Volume budgets. Mass, CoG and inertia (MCI) properties of the undeployed and deployed morphing system coupling with Flying Qualities, Mission and GNC needs

• Specific subsystems sizing

System design (1/2): Overall concept

CES

MDO

Morphing

Features

Detailed

Design

System design (2/2): Baseline subsystems

FPCS ongoing design activity:

including: EMAs, levers, flap rods, EMACU,

batteries

RCS ongoing design activity:

several thrusters to get roll, pitch and yaw

motion control.

Parachutes altitude-Mach envelope and limiting

factors definition.

Gas Generator (inflatable sidewalls)

Requirements:

• pinfl=120kPa constant within the bags,

• tinfl<2s.

Pyrotechnic ignition: sodium azide+additives,

reaction time 20÷40ms (vol. 45-120l) << tinfl,

reaction temperature 1100÷1350°C,

temperature after expansion 150°C.

MASS BUDGET (propellant+casing+valves including

20% SM): 245 kg each side TOT 490 kg.

Main goal:

Ensure safety in case of abort condition

Trajectory (including morphing) is optimized at multiple abort points along the SL7 trajectory

Optimization is done with the objectives of:

• Improve passengers safety (Extend range flown => simplify rescue operations)

• Improve passengers comfort (Reduce thermo-mechanical loads on the capsule)

• Improve and guarantee appropriate Flying Qualities (Trim, Stability, Control) for GNC

Mission and GNC: reconfiguration (1/2)

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Mach Number [-]

SpaceLiner Nominal Trajectory

Full Configuration Ascent

Orbiter Ascent

Orbiter Descent

Hypersonic Regime

Booster

Separation Orbiter

MECO

SGRA optimization results for MECO Abort Point

Mission and GNC: reconfiguration (2/2)

Main goal:

Ensure robustness against morphing

Selected control approaches: Time-varying parameter impacting the dynamics

Robust control (H∞, ) can

directly tackle the synthesis

problem for uncertain systems

However, time-varying

parameters are regarded as

constant and unknown

Control design

framework

Robust control

LPV control

Information available regarding

the parameters can be used– Time-varying

– Rate bounded/unbounded

The “morphing parameter”,

which is assumed measurable,

can enter directly the synthesis

problem

• Meshing

• Convergence

Aerothermodynamic analyses (1/2)

Hexa box (flaps interaction)

Many refinement sources

(shock, rear flow)

- ~13 millions cells

- 256 procs used

- ATD coeffs accuracy < 0.0002

- 60.000 to 100.000 iterations

Aerothermodynamic analyses (2/2)

Phi < 805 kW/m²

Nose

Phi < 570 kW/m²

Rudders

Phi < 400 kW/m²

IADs

Phi < 600 kW/m²

Phi < 450 kW/m² (In the major part of the flaps)

Flaps

ID Vehicle AoA Elevator AoS Aileron Scope Phase #588 Name

5 Baseline 20 0 -10 0 Sideslip DL2 ID5_DL2

Inflatable sidewalls

Concept view

Structures and materials (1/2)

INFLATABLE SIDEWALLS DESIGN:

Materials:

Nextel: th: 2 mm× 6 layers

Saffil: th: 8 mm × 2 layers

Pyrogel: th: 3 mm× 2 continuous layers

th: 3 mm× 3 discontinuous layers

(T300J carbon fiber: 2 layers)

Total Mass: 1165 kg (each side)

• Complex dynamic simulations

• Complex optimization of bags and

membrane solution (flexible but

robust & stable TPS barrier)

LS-Dyna simulations:

work in progress!Stowed / Deployed configuration

Thermal Analyses

Inflation time: 2s

Flaps and Rudders

Structures and materials (2/2)

Deformation

Analysis

Thermal Analysis

Thermal

Analysis

RUDDERS DESIGN

• Materials: C/C-SiC main bodies with

Saffil insulation at vehicle I/F

• Total mass = 60 kg (each)

• Deployable system: spring & lock

Deformation Analysis

FLAPS DESIGN

• Materials: C/C-SiC main bodies

with local UHTC washers

• Total mass = 86 kg (each)

No hypersonic aircraft is currently in operation. Due to this lack of experience and

because of the complexity of the system and other risk sources inherent to this kind

of system it is deemed essential to provide an escape system in order to bolster the

reduced level of reliability.

Morphing allows increasing the vehicle aerodynamic performance: provides the

system with the necessary robustness to adapt to a changing environment.

This translates into safer flight conditions for passengers in case of emergency

situations. Improved aerodynamics allow for:

• Longer trajectories (easier to reach a safe landing point)

• Lower thermo-mechanical loads (increased passenger comfort)

• Trimmable, stable and controllable flight

The improved safety is considered essential in order to increase acceptance of this

kind of trans-atmospheric transportation by potential customers.

Multiple technological challenges have been approached improving the European

knowledge in designing a complex hypersonic morphing system at multiple levels

(system, GNC & MA, structure and materials, aerothermodynamics).

Impact

Innovative hypersonic inflatable and deployable morphing solutions have been conceived, studied and optimized.

Integration of a mass-volume-power efficient morphing subsystem is extremely challenging.

The problem is multi-disciplinary in nature and requires a highly coupled interaction between conflicting objectives and requirements.

The project is in its last step in which the detailed design of the hypersonic morphing CES will be completed.

A workshop on hypersonic morphing with more detailed insight on the activities performed in the HYPMOCES project is planned on:

26th November 2015

The research leading to these results has received funding from the European Union's Seventh Framework Programme FP7/2007-2013 under grant agreement nº AAT-2012-RTD-341531 entitled “Hypersonic Morphing for a Cabin Escape System (HYPMOCES)”.

Conclusions

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