IRENE PROGRAM

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Aerospace Laboratory for Innovative components IRENE PROGRAM I I talian talian R R e- e- E E ntry ntry N N acell acell E E Preliminary Study Preliminary Study 1 1 0th INTERNATIONAL Planetary Probe WORKSHOP 0th INTERNATIONAL Planetary Probe WORKSHOP June 17-21, 2013 June 17-21, 2013

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IRENE PROGRAM. I talian R e- E ntry N acell E Preliminary Study. 1 0th INTERNATIONAL Planetary Probe WORKSHOP June 17-21, 2013. BACKGROUND OF THE ACTIVITY (1/2). - PowerPoint PPT Presentation

Transcript of IRENE PROGRAM

Page 1: IRENE PROGRAM

Aerospace Laboratory for Innovative components

IRENE PROGRAM

IItalian talian RRe-e-EEntry ntry NNacellacellEE Preliminary StudyPreliminary Study

110th INTERNATIONAL Planetary Probe WORKSHOP0th INTERNATIONAL Planetary Probe WORKSHOP June 17-21, 2013June 17-21, 2013

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Aerospace Laboratory for Innovative components

BACKGROUND OF THE ACTIVITY (1/2)

The Italian Space Agency (ASI) is supporting since 2010 a research programme, called IRENE, in Campania (ALI, South of Italy), to develop a low-cost re-entry capsule, able to return payloads from the ISS to Earth and/or to perform short-duration, scientific missions in Low Earth Orbit (LEO).

The main features of the IRENE capsule are:

• light weight (100-200 kg), 3 m fully deployed

• payload recoverability and reusability

• a low-cost, deployable, disposable heat shield composed by:

o a fixed nose (made by ceramic or other equivalent TPS)

o a deployable aero-brake (umbrella-like, made by special multi-layered fabric).

ALI - Aerospace Laboratory for Innovative components is as a Consortium of17 Companies operating within the fields of design, engineering,

prototyping and realization of innovative aerospace sybsystems and Ground Segment for technological

and scientific platforms

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Aerospace Laboratory for Innovative components

BACKGROUND OF THE ACTIVITY (2/2)

The feasibility study of this deployable re-entry system has

been carried out in 2011.

The TPS materials, selected for the nose cone and for the

flexible umbrella shield, have preliminarily been tested in the

SPES hypersonic wind tunnel at the University of Naples, and

in the SCIROCCO PWT (Plasma Wind Tunnel) at CIRA (Centro

Italiano Ricerche Aerospaziali) of Capua, Italy.

IRENE TPS test in the SCIROCCO Plasma Wind Tunnel at CIRA

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Aerospace Laboratory for Innovative components

MINI-IRENE DEMONSTRATOR (1/2)

On the basis of the previous results, ESA supported a six months "Bridging Phase” to preliminarily address the main issues of a MINI-IRENE demonstrator to be embarked as a piggy-back payload for a future mission of a sub-orbital MAXUS sounding rocket.

The Mini-IRENE system shall be boarded as a secondary payload in the inter-stage adapter of the rocket and ejected, at an altitude of about 150 km, to perform 15 minutes ballistic flight.

A possible launch of a demonstrator of IRENE from a sounding rocket will require scaling down the most important parameters

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Aerospace Laboratory for Innovative components

MINI-IRENE DEMONSTRATOR (2/2)

Considering a cylindrical volume available with D=29 cm, h=25 cm, mass≈15-20 kg, the following issues have been addressed:

Analysis of the time profiles of the different physical parameters of interest (e.g. pressure, temperature, acceleration).

Preliminary aerodynamic and aero-thermodynamic analysis (engineering methods and CFD analysis of 45 and 60 deg half cone)

Identification of the main mission requirements and corresponding subsystems

Trade-off between different configurations and identification of possible solutions for the different subsystems.

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Aerospace Laboratory for Innovative components

AEROTHERMODYNAMIC ANALYSIS

Altitude versus time Acceleration versus time Altitude versus stagnation pressure

Pressure distributions at maximum dynamic pressure condition (left: maximum

21 kPa, right: maximum 10.5 kPa)

Half-cone angle [°]

D [m] S [m2] cD = m/(cD*S)

60 1 0.79 1.4 18

45 0.84 0.58 1.03 33

Main geometric and aerodynamic characteristics

same length of the poles

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Aerospace Laboratory for Innovative components

MINI-IRENE REQUIREMENTS

Compatibility with MAXUS inter-stage

Maximum diameters of 29cm (folded) 100cm (deployed)

Total mass below 20 kg / Ballistic coefficient less than or equal to 18 kg/m

Deployable heat shield

Attitude correction before deployment

Automatic system for TPS deployment (during exo-atmospheric phase) generating a 45-60 deg sphere-cone shape

Structure able to withstand mechanical loads at launch and aerodynamic loads during reentry (10000 Pa stagnation pressure, 40g deceleration, impact loads at landing with a velocity in the order of 20 m/s)

TPS able to withstand heat fluxes in the order of 350 kW/m2

CoG location to guarantee stability and reduce trim angle

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Aerospace Laboratory for Innovative components

Three possible solutions have been considered for the supporting structure:

Telescopic poles

Folded arms

Hinged arcs

Any of the solutions foresees upper and lower threads to give

rigidity to the whole system and a mobile structure (≈ Tensegrity)

Sufficient room, within the dedicated Maxus volume, is left for the

TPS fabrics that must stay properly bended before the deployment

In the present preliminary design all constructions includes a series

of 12 main elements (poles, arms or arcs) but this number may vary

PRELIMINARY DESIGN OF THE SUPPORTING STRUCTURE

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Aerospace Laboratory for Innovative components

Solution 1: 12 telescopic poles

Closed

telescopic poles

Upper threads

Sliding structure

Fixed structure

Lower threads

a1) folded structure; b1) pole elongation phase; c1) tensioning phase

• Poles hinged to sliding structure

• Upper threads anchored to fixed structure

• Lower threads anchored to sliding structure

Elongated

telescopic poles

Multi layer TPS fabric

Nose (ceramic) TPS

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Aerospace Laboratory for Innovative components

Solution 2: 12 foldable arms

10

a2) folded structure; b2) arm extension phase; c2) tensioning phase

Two-segment

foldable arms Upper threads

Sliding structure

Fixed structure

Lower threads

• Arms hinged to fixed structure

• Upper threads anchored to fixed structure

• Lower threads anchored to sliding structure

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Aerospace Laboratory for Innovative components

Solution 3: hinged arcs

Bended arcs of ring

Double

Universal joints

Lower threads

Fixed structure

Sliding structure

Upper threads

a3) folded structure; b3) rim extension phase; c3) tensioning phase

Example of double universal joints. Similar joints could be used to connect the elastic arcs of the ring

• Arcs hinged one another

• Upper threads anchored to fixed structure

• Lower threads anchored to sliding structure

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Aerospace Laboratory for Innovative components

TPS PRELIMINARY DESIGN

The TPS will be composed by two main sections:

- a rigid nose

- a flexible part, to be deployed prior to re-entry.

The flexible part of the heat shield is not requested to function much as a thermal insulator but, rather, mainly as an aero-brake.

The deployable part of the thermal shield should be sufficiently thin and flexible for an easy deployment.

It will be necessary to prove that the exposure of the proposed materials to the typical heat fluxes expected during descent would not compromise the tensile strength of the flexible part of the heat shield.

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Aerospace Laboratory for Innovative components

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PRELIMINARY DESIGN OF DEPLOYMENT MECHANISM (1/2)

Two different mechanisms have been considered to deploy the IRENE aerobrake/heat shield:

• Mechanism #1: Including actuator springs and gas dampers

• Mechanism #2: Including a gas actuator

Description of Deployment Mechanism #1

This solution exploits harmonic steel compression springs that, once loaded, store the needed mechanical energy to perform the heat shield deployment. In order to avoid abrupt elongation of springs as they are unlocked, a damping system has been devised.

Description of Deployment Mechanism #2

The second deployment mechanism which has been devised in this preliminary study exploits a high-pressure gas working as an actuator spring upon a liquid that performs the displacement. In facts, the gas is initially contained in a bottle, under high pressure (not much differently from the gas reservoirs of compressed air guns).

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Aerospace Laboratory for Innovative components

PRELIMINARY DESIGN OF DEPLOYMENT MECHANISM (2/2)

View of the heat-shield structure after the deployment mechanisms have been operated (solution 1: telescopic poles)

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Aerospace Laboratory for Innovative components

A FEM structural analyses has been performed for each of the three identified solutions. The main goal of the activities is the evaluation of the stability and the stress levels in the most critical components of the three solutions. The components so identified, are as follows:

Poles (sol. #1), arms (Sol. #2) and arcs (Sol. #3);

Threads

TPS Fabric layers (FEM models, four layers of NEXTEL AF-10, thickness=0.39 mm).

Results: admissible stress levels for the structural components (considering also the operating temperature) is the following:

Titanium structure 400 MPa at 400°C

NEXTEL Fabric : 40 MPa at 900 °C

STRUCTURAL ANALYSIS

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Aerospace Laboratory for Innovative components

The solution #1 (with 45 deg half cone) shows a better behavior for the following aspects:

SOLUTION SELECTION

Better aerodynamic stability, due to smaller cone angle (45° instead of 60°)

Largest diameter of the deployed structure due to the deploying mechanism kinematics

Better fabric tension distribution after the deployment phase due to deploying mechanism kinematics

Lower fabric deflection under the re-entry pressure loads

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Aerospace Laboratory for Innovative components

INSTRUMENTATION

The most important parameters to be quantified during the re-entry are the aerothermodynamic loads, represented by the surface pressure distribution and the surface heat flux.

The main assumption is that the payload consists only of the following sensing elements and their respective data acquisition and storage electronics and power supply:• Thermocouples• Pressure transducers • Linear and angular acceleration sensors• Strain gages• Telecommunications subsystem• On Board Camera and Sound Recording• On Board Data Handling

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Aerospace Laboratory for Innovative components

Sensors: thermocouples location

Payload temp.

Computer temp.

Cone shape

Nose

1° ribs point

2° ribs point

3° ribs point

1° umbrella point

2° umbrella point

3° umbrella point

1° nose point 2° nose point 3° nose point 4° np

5° np

3° ext. body

2° ext. body

1° ext. body

• 2-3 thermocouples at the stagnation point at different depth

• 2 thermocouples embedded in outer positions of the nose cone

• 3 thermocouples at different positions of the flexible shield, (embedded in the last inner textile layers).

• 3 thermocouples located out of the capsule body, and 2 inside the payload area

• 3 thermocouple will monitor the ribs heating.

INSTRUMENTATION: THERMOCOUPLES

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Aerospace Laboratory for Innovative components

Sensors: pressure sensors location

Cone shape

Nose

2° Back shield

1° nose point 2° nose point 3° nose point

1° Back shield

2° ext. body

1° ext. body

• 3 pressure sensors embedded at the stagnation point and in (2) outer positions of the nose cone.

• 2 pressure sensors located at different positions out of the capsule body, inside the “cone area”.

• 2 pressure sensors located on the back shield of the capsule body.

INSTRUMENTATION: PRESSURE SENSORS

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Aerospace Laboratory for Innovative components

Telecommunication / Data Retrieval

No TMTC. Recovery of the capsule via beacon (to be choosen/developed/upgraded).

GNC Trajectory measurement by use of MEMS based IMU and eventual additional axial accelerometer for high accelerations.

Data Handling Preferably COTS electronics. Possibly merged with power conditioning / distribution to provide miniaturization. 1 Processor boards (OBC, Payload) 2 Analog acquisition board , 1 output board

Data concept Recoverable on board recording, no Telemetry

Image and sound recording

The presence on board of a video camera and a microphone is useful as additional check on the functioning of the experiment.

Power Primary batteries only

AVIONICS AND INSTRUMENTATION

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Aerospace Laboratory for Innovative components

• No telemetry

• A beacon system will be used for the recovery after landing

• The beacon shall be operational before landing

• The beacon shall be operational after a landing for at least 48hours

• The use of standard call and Search and Rescue system, such as Cospas-Sarsat, is allowed

• The baseline configuration is “integrated Beacon with antenna out of back TPS”

Trade-off compared and help to select COTS beacon.

Main issues are:

•Small and light equipment.

•Crushability requirements are critical, in order to avoid previous “Shark mission” impact problems

•Power autonomy for at least 48hours

TELECOMUNICATION

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Aerospace Laboratory for Innovative components

Trade-off compared and help to select the GNC equipment that better match mission requirements. Two different options:

•Individual accelerometers and gyroscopes selected independently (no IMU) (best solution: solution n. 2 is not readily usable because of the difficulty of interfacing with the OBDH system selected).

•Integrated IMU with an acceleration range of more than 40g

• To acquiring flight parameters and reconstructing flight trajectory of the capsule

• Acceleration requirement of a minimum of 40g, (maximum re-entry Acceleration)

• Detection of linear and rotation rate of acceleration

• Minimize mass and weight

GNC

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Aerospace Laboratory for Innovative components

The Vehicle Memory Unit (VMU) is one of the most critical part of the mission: it will store all data and has to survive the crash-landing.

Two design possibilities have been evaluated:

•Embed the VMU in the Data Handling System. DHS can provide sufficient memory to allocate the whole mission data. The whole DHS have to survive the crash-landing.

•Consider the VMU as a separate unit with an external interface to the DHS.

1) In previous “Shark” mission, the first configuration was selected (flight proven, ACRA KAM 500 modular computer, able to acquire and store, on a ruggedized memory unit, all the data)

2) Other projects (“Phoebus”) in order to be more resistant to crash, decided to implement the VMU as a separate unit interfacing the DHS using USB bus.

ON BOARD DATA HANDLING

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Aerospace Laboratory for Innovative components

Preliminary functional diagram

Supply Module

AnalogModule

Thermocouple(K) Module

VMUData storage

Module

backplane controller

Conditioning electronics

Accelerometers

Gyroscopes

ThermocouplesPressureTransducers

+/-12V

+/-12V 6x +/-5V

6x +/-100mV

Ch

an

ne

l 1

1-1

6

10

x (

0

- 1

00

mV

)

10

V 1

00

mA

Ch

an

ne

l 1

-10

Power switch

MAIN BATTERY6 x (3.6V 5.8Ah)

MAXUS-8Switch

Interface

Power Circuit

ELTBeacon

BeaconBattery

BeaconAntenna

21V

21V 10mA

3V 500mA

OBDH - DHS

15

x (0 - 5

0m

V)

21V 560 mA

Beacon

IMU

Discrete outputModule

To parachute deployment

To thermal shield

deployment

PRELIMINARY DEFINITION OF AVIONICS AND INSTRUMENTATION (8/8)

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Aerospace Laboratory for Innovative components

PRELIMINARY TOTAL MASS BUDGET

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Aerospace Laboratory for Innovative components

Future Development

About development plan for the MINI IRENE project up to launch, presently planned in the first half of 2015, is detailed below. It includes the already performed Preliminary Study (referred to as “Bridging Phase”, BP, in the figure below) which concludes the Phase 0 studies previously performed on behalf of ASI.