www.dlr.de Chart 1 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 SHEFEX II 2nd Flight within DLR s Re-Entry Technology and Flight Test Program The SHEFEX Team
www.dlr.de Chart 2 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 Andoya, Norway June, 22nd 2012, 21.19 CEST
www.dlr.de Chart 3 DLR`s Re-Entry Program, Why? - Re-entry or return technology respectively, is a strategic key competence which becomes obvious after retirement of the Space Shuttle fleet. - Currently, the German industry and DLR is well experienced and prepared within all related disciplines due to a lot of recent development programs. - Within DLR CMC based thermal protection systems are available up to a technology readiness level of 6 to 7 - Within the SHEFEX/REX Development program all related scientific disciplines like materials and structures, TPS, flight control, GNC and aerodynamics are linked together to develop and test in flight new technologies for innovative space crafts with enhanced re-entry capability.
www.dlr.de Chart 4 SHEFEX-Concept, Why? - Reduction of manufacturing and maintenance costs of the thermal protection system up to 50% due to facetted shape and flat TPS elements - Sharp edges allow optimized hypersonic aerodynamic performance with lower drag and enlarged cross range or re-entry flexibility respectively - Scale able aerodynamic performance at hypersonic velocity. - Low angle of attack and defined shock geometry reduces communication black-out - A mission optimized return vehicle shall be possible classic, high angle of attack optimized low angle of attack
www.dlr.de Chart 5 Returnable Spacecraft Technology Flight Tests Running activities CMC Nose Cap System on EXPERT (ESA) TPS Experiments on FOTON Missions CMC Fin Experiment on HIFIRE 5 and ablative stabilizer leading edge on HIFIRE 3 & 5 CMC Stabilizer Fins within SCRAMSPACE (UQ/DSTO Australia) SHEFEX Flight test program Vortrag > Autor > Dokumentname > Datum
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www.dlr.de Chart 7 Location of DLR Competences for SHEFEX Bremen: Mission analysis, Navigation technology, Avionics Braunschweig: Aerodynamic vehicle layout, Interstage Structures, aerodynamic control system, Göttingen: Hypersonic Wind Tunnel Tests Köln: Instrumentation and Hypersonic Wind Tunnel Tests, oxide based TPS Institute of Space Systems Bremen Braunschweig Institute of Aerodynamics and Flow Technology Göttingen Köln-Porz Institute of Materials Research Institute of Flight Systems Stuttgart: Program coordination, Vehicle design, TPS and Hot Structures, Fairing and fin structures Oberpfaffenhofen: Rocket Design, Subsystems, RCS-Control, Launch Operation Stuttgart Institute of Structures and Design Oberpfaffenhofen Mobile Rocket Base
www.dlr.de Chart 8 Partners of SHEFEX II
www.dlr.de Chart 9 SHEFEX and synergy effects with other Programs Examination of sharp leading edge structures 3 different materials 1500.0 C 1500 1000 500 250.0 C
www.dlr.de Chart 10 SHEFEX-Programm SHEFEX I Pathfinder-Mission Suborbital Rocket system VSB 30 /Imp. Orion Mass approx. 250 kg Velocity Ma 6, duration 20 s Successful flight in 2005 Unique free flight test data Large amount of lessons learnt 2 External passengers
www.dlr.de Chart 11 SHEFEX-Program SHEFEX I SHEFEX II Suborbital Rocket system VS 40 (brasilian) Controlled hypersonic flight Mass approx. 500 kg Velocity Ma 10 Re-entry duration 50 s Successful Flight 2012 4 External passengers
www.dlr.de Chart 12 SHEFEX I versus SHEFEX II Re-entry velocity rises from 1.4 km/s to 2.8 km/s Experiment duration rises from 15 s to 50 s Acitive flight control during entry phase (100-20 km) Facettet, symmetric payload tip Measurement also during ascent phase Extension of instrumentation and experiments SH II SH I
Altitude of vehicle above s ea level [km] www.dlr.de Chart 13 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 SHEFEX 2 Basic Mission Scenario 300 250 200 150 100 50 -Precessio n Manoeuvre -1st Stage Burn -2nd Stage Burn Phase 468 521 -Desepin, -Fairing Release, Star Track and ACS Manoeuvre -Experimen t Phase Trj 800 Trj 900 100 20-1st stage burn phase t=62sec - Precession manoeuvre tmax 120sec - 2nd stage burn phase t 70sec - Despin, Fairing Release, Star Update and ACS manoeuvre for reentry attitude - Experiment phase from 100km to 20km t 53sec - Recovery sequence starting w/ P/L split in approx. 14km altitude 0 100 200 300 400 500 600 700 800 Phase Flight Time [s ec.] cv -Recover y
Altitude of vehicle above sea level [km] www.dlr.de Chart 14 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 SHEFEX 2 Preliminary Altitude vs. Ground Range 300 662 783 Trj 800 Trj 900 Reentry Angle 200 100 - δ 35 100 -Experiment Phase 20 0 100 200 300 400 500 600 700 800 900 1000 Ground Range over Earth curvature [km] Apogee Trj800 (Baseline) h 194km Ground range GR 800km Reentry angle δ 35 Ground range Experiment Phase GR exp 120km cv
Mach No. & Alt [10km] & q [10^4Pa] www.dlr.de Chart 15 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 SHEFEX 2 Predicted Reentry Parameter 12 10 8 6 -Experiment Phase -Mach Regime Mach No. 800 [-] Alt 800 [10km] Mach No. 900 [-] Alt 900 [10km] Dyn. Press. 800 [10^4 Pa] Dyn. Press. 900 [10^4 Pa] - Mach No. regime M 10.3 to 8.7 - Experiment time from 100 to 20km t exp 53sec - Max. dynamic pressure up to 900 kpa at P/L split - P/L split at h 15km (M 9) - Begin of both recovery sequences at h 4.6km 4 2 -P/L Split and Recovery 460 480 500 520 540 560 580 600 620 Flight time [sec] cv
www.dlr.de Chart 16 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 Complete Vehicle Layout - Overview S40 S44 Vehicle consists of S40/S44 motor combination w/ modified tail can and fins Interstage adapter with active stage separation system Motor adapter equipped w/ destruct and separation system Experiment fins covered by CFK split fairing (l= 1.6m) Total length l= 12.741m Total mass m 6800kg
www.dlr.de Chart 17 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 -Complete Vehicle Layout - Detail
www.dlr.de Chart 18 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 Precession Vehicle Layout Mass & Dimensions - Complete experimental P/L w/ S44 motor and fairing - Length 6925 mm (excl. Nozzle extension) - Mass 1574 kg - Ipol 154 kgm² - Ilat 4558 kgm²
www.dlr.de Chart 19 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 Experiment Vehicle Layout - Modules -Split -Plane - Facetted symmetric forebody w/ five sections a 300mm - Canard control in Actuator Module - Gas Module #1 w/ precession thrusters - Service Module w/ Antennae - Main Recovery Module - P/L Split/Separation System - YoYo and Fairing Release Ring - Gas Module #2 w/ 4 gas tanks - Conical Adapter w/ Aft Recovery System & ACS thruster - Motor Adapter w/ roll control thrusters Folie 19 > SHEFEX2 DLR, Weihs 21.08.08
www.dlr.de Chart 20 Experiments on SHEFEX II New ablative fin structure Hybrid navigation system Aerodynamic control Instrumentation, TC, Heatflux, pressure, Pyrometer, Compare (IRS) Hybrid CMC/Metallic Canards Windtunnel testing 9 TPS Systems (ASTRIUM, MT-A, AFRL, DLR) 1 actively cooled segment 4 Hot Antennas
www.dlr.de Chart 21 SHEFEX II: Determination of Aerodynamic Data Base (numerical and wind tunnel testing)
www.dlr.de Chart 22 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 Overview of the Payload Tip and Instrumentation -Pressure sensors -Pyrometer -CMC-TPS -Heat flux sensors -Metallic-TPS -Alu substructure -Pressure sensors -FADS -Electronic boxes for -CMC-Tip -Pressure sensors -Heat flux sensors -sensor data processing -CMC-TPS -COMPARE Spectrometer
www.dlr.de Chart 23 Hardware: CMC Serial production SHEFEX Program Team Weihs 23
www.dlr.de Chart 24 Material and Thermal Protection Experiments Oxide based CMC Elements for Antenna Inserts Actively cooled TPS Element CMC Nose Tip including Pressure ports for FADS SHEFEX Program Team Weihs 24
www.dlr.de Chart 25 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 Instrumentation -Surface thermocouples Temperature distribution of the vehicle using radiation adiabatic boundary condition turbulent boundary layer, Alt 20 km, Ma 8, α = 2.5
www.dlr.de Chart 26 SHEFEX II, Hardware: Instrumentation
www.dlr.de Chart 27 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 Flush air data system (FADS) experiment > Measurment of static pressure at 8 locations > Development of algorithm for determination of gas flow orientation > Calibration within hypersonic wind tunnel facility > Comparison to navigation platform results Monolithic CMC nose insert with integral pressure ports
www.dlr.de Chart 28 SHEFEX II: Aerodynamic Flightcontrol
Mechanical and Thermal Interface Umbilical Cord Reset Umbilical Cord Telemetry / Telecommand Ready for Star Tracker Data Interface Lift Off Mechanical and Thermal Interface Mechanical and Thermal Interface Mechanical and Thermal Interface GPS Signal www.dlr.de Chart 29 Hardware: Hybride Navigation System (Experiment) CCC Canard Control Computer Signal Line RS422 Physical Interface -Power Distribution Firewire Power Trigger (1 Hz) -GPS Receiver Command, Data (2 Hz), PPS Star Camera Command, Data (1HZ) Power ST Computer Command, Data (1 Hz) Navigation Computer (NC) Command, Data (500 Hz) Trigger (500 Hz) IMU GPS GPS Signal GPS Antenna Mechanical and Thermal Interface -Camera Baffle and -Shutter Release DC/DC Iso. D-Box PDU Vehicle
www.dlr.de Chart 30 SHEFEX: Secondary structural Experiments Ablative stabilizer fins CFRP Fairing with integrated ablative TPS Hybrid Al/CFRP stabilizer fins Hybrid TI/CMC Canards
www.dlr.de Chart 31 After numberous ground and qualification tests: SHEFEX II on Tour
www.dlr.de Chart 32 > AIAA 2012 Tours > Weihs Dokumentname > 26.9.2012 Andenes, Norway
www.dlr.de Chart 33 payload assembly hall Andoya Rocket Range, Norway control center rocket assembly hall block house launch pad
www.dlr.de Chart 34 SHEFEX II Trajectory and Impact areas
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www.dlr.de Chart 36 Flight events logic
www.dlr.de Chart 37 SHEFEX II predicted Flight Conditions
www.dlr.de Chart 38 Payload integration
www.dlr.de Chart 39 Motor preparation First stage Second stage
www.dlr.de Chart 40 Preparing the launcher
www.dlr.de Chart 41 After - 5 hard Years of development -16 Million Euros -20 `24 hours`days campaign duration -Uncounted coffees, pizzas, bavarian and swabian Beers SHEFEX II was ready for flight
www.dlr.de Chart 42 Final Count Down Launch Control System Control Experiment Control
www.dlr.de Chart 43 3, 2, 1, ignition
www.dlr.de Chart 44 Telemetry and Radar Tracking, 600 exiting seconds
www.dlr.de Chart 45 Shefex II Trajectory, GPS Data
www.dlr.de Chart 46 -AKTIV Panel
www.dlr.de Chart 47 Results: AKTiV - active cooling: severe thermal environment - outer structure porous - two effects: convection & film cooling - AKTiV: one panel cooled, one uncooled
first stage separation second stage ignition 110km altitude Gas on 30km www.dlr.de Chart 48 T cooled -Results: AKTiV - cooling effect visible during return flight - cooling efficiency h=(1-t c /T uc ) up to ~50% T uncooled
www.dlr.de Chart 49 SHEFEX II Mission Accomplished First results - Trajectory flown as planned (deviation <1%) - All vehicle maneuvers successful - All experiments got data during ascent and re-entry - Max. velocity 2.8 km/s - Assessment of flight data will cover the next years However - Hardware is lost due to changing weather conditions at landing site
www.dlr.de Chart 50 Thanks to the team!!!
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www.dlr.de Chart 52 SHEFEX-Program, next Step - SHEFEX I - SHEFEX II - SHEFEX III REX Down scale SHEFEX III Suborbital Mission Demonstrating an optimized trajectory Rocket system VLM/S-50 (brasil.) Mass approx. 500kg Velocity approx. Ma 24 Re-Entry duration approx. 15 Min In preparation DLR lead, external partners
www.dlr.de Chart 53 SEFEX III: Aerodynamic data base (derived from REX shape)
www.dlr.de Chart 54 Flight regime α=52 max. lift α=75 (first 900sec), α=14 max. range Viking Shuttle max. C A Δv 3000 m/s SHEFEX 1 SHEFEX 2 SHEFEX 3 max. C A /C W
www.dlr.de Chart 55 VLM: Launch vehicle for SHEFEX III S-50 S-50 S-44 Length: ~18 m, Diameter: 1.4 m, Mass: ~26 tons Launch Site:Alcantara(Brazil) Impact:Southwest of Cap Verdean Islands Re-Entry Capacity: ~ 570 kg @ 100km Altitude @ 6.5 km/sec
www.dlr.de Chart 56 Thank you! Vortrag > Autor > Dokumentname > Datum