Professional Documents
Culture Documents
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
Contents
Origin of structural requirements Spacecraft configuration examples Structural configuration examples General arrangement drawings Launch vehicle interfaces and volumes Structural materials Subsystem mass estimation techniques Vibration primmer Developing limit loads for structural design Sizing the primary structure Structural subsystem mass
pg 3 pg 8 pg 14 pg 25 pg 30 pg 33 pg 38 pg 51 pg 59 pg 68 pg 73
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
Launch Vehicle
3
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
MECO SECO
1st stage
2nd stage
3rd stage
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
Orbit Loads
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
The sun in the orbit plane changes due to the seasonal change in the suns declination (the tilt in the Earths axis) and orbit plane precession due to the Earths equatorial bulge. At 35o inclination, the precession period is ~ 55 days
R.Farley NASA/GSFC
Feb 16 2005
ENAE 691
EOS aqua
one oar in the water produces an aerodynamic torque that averages to zero per orbit, but reaction wheels must be large enough to absorb in the interim
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
10
TDRSS A
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
IMAGE 2000
12
Sun shield
MAP at L2
Sky surveys in the ecliptic plane
Lunar Prospector
Body-mounted s/a
Cassini to Saturn
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
13
transition structures and interfaces extending a hard point (picking up point loads)
Trusses
As much as possible, payload connections should be kinematic Skin Frame, Honeycomb Panels, Machined Panels, Extrusions
NOTE: ALWAYS PROVIDE A STIFF AND DIRECT LOAD PATH! AVOID BENDING! STRUCTURAL JOINTS ARE BEST IN SHEAR!
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
14
Structural examples
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
15
Structural examples
16
Structural examples
17
Structural examples
EOS aqua, bus
18
Structural examples
COBE STS version 5000 kg ! COBE Delta II version
2171 kg !
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
19
Structural examples
TRIANA L1 orbit
20
Anatomy of s/c
Axial viewing, telescope type
Interface isolation Reaction structure wheels
Astronomy Mission
Station-keeping hydrazine, polar mount Solid kick motor, equatorial mount
Bus module
Propulsion module
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
21
Modular Assembly
Instrument Module optics, detector Bus Module (house keeping) Propulsion Module Modules allow separate organizations, procurements, building and testing schedules. It all comes together at observatory integration and test (I&T) AXAF
22
2,2,2
Hexapod arrangement
1,1,1,1,1,1 1 3 2
Rod flexures arranged in 3,2,1 Breathes from point 3
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
23
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
24
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
25
Omni antennas
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
27
Pegasus Interface
28
Payload Envelope
For many vehicles, if the spacecraft meets minimum lateral frequency requirements, then the static envelope accounts for fairing dynamic motions.
STATIC ENVELOPE; the space that the
payload must fit inside of when integrated to the vehicle
If frequency requirements are not met, or for protrusions outside the designated envelope, Coupled Loads Analysis (CLA) are required to qualify the design, in cooperation with the LV engineers.
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
29
Clamp-band
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
30
Structural Materials
Material
Aluminum 6061-T6 7075-T651 Magnesium AZ31B Titanium 6Al-4V Beryllium S 65 A S R 200E Ferrous INVAR 36 AM 350 304L annealed 4130 steel Heat resistant
Non-magnetic
Metallic Guide
(m/m K)
(kg/m3) 2800 2700 1700 4400 2000 8082 7700 7800 7833
Fty (MPa) 276 503 220 825 207 345 620 1034 170 1123
E/
Fty/
(W/m K)
24 26 26 25 151 18.5 26 25 25
14 40-60 16 48
25 24 25
16.4 23.0
12 12 31
R.Farley NASA/GSFC
specific stiffness, the ratio of stiffness to density specific strength, the ratio of strength to density coefficient of thermal expansion CTE coefficient of thermal conductivity
INVAR has the lowest coefficient of thermal expansion, but difficult to process Titanium has the lowest thermal conductivity, good for metallic isolators
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
32
Applications
Aluminum
Titanium
High strength to weight, low CTE, low thermal conductivity, good at high temperatures
Steel
Heavy, magnetic, oxidizes if not stainless steel. Stainless galls easily Heavy, difficult to machine
Heat-resistant Steel
Beryllium
Feb 16 2005
Synthetic aperture radar ~ 32 Rain radars ~ Cameras ~ Small instruments ~ 150 500 1000 thickness / diameter ~ 0.2 Small telescopes w/ camera ~ 325
Scaling Laws: If a smaller instrument exists as a model, then if SF is the linear dimension scale factor Area proportional to SF2 Mass proportional to Stress proportional to SF
34
SF3
Communication S-band omni antenna S-band transponder X-band omni antenna X-band transmitter Parabolic dish reflector 2-axis gimbal Gimbal electronics Diplexers, RF switches Band reject filters Coaxial cable Thermal Radiators Louvers Heat pipes Blankets Heaters Heat straps Sun shield Cryogenic pumps Cryostats
ENAE 691
Power Batteries Solar array panels Articulation mechanisms Articulation electronics Array diode box Shunt dissipaters Power Supply Elec. Battery a/c ducting Propulsion Propulsion tanks Pressurant tanks Thrusters Pressure sensors Filters Fill / drain valve Isolator valves Tubing
R.Farley NASA/GSFC
52 %
14 %
8%
8%
2%
3%
1%
37 %
22 %
7%
6%
0.5 %
2%
2%
2%
13-20 %
30 %
7%
14 %
1%
3%
15 % 2-axis gimball
0%
Mass fractions as percentage of total spacecraft observatory mass, less fuel COBE with 52% payload fraction is unusually high and not representative
ACS is Attitude Control System, C&DH is Command and Data Handling, Comm is Communication subsystem
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
36
Structural subsystem (primary, secondary) Propulsion fuel mass, if required Power subsystem Define ratio mi = Mi / Mdry
Mdry = mass of spacecraft less fuel Remember to target a mass margin of ~20% when compared to the throw weight of the launch vehicle and payload adapter capability. There must be room for growth, because evolving from the cartoon to the hardware, it always grows! The following slides will show the cheat-sheet for making preliminary estimates on some of these subsystems
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
37
mpayload ~ 0.4(large sat) ~0.2(small sat) for a first guess ratio Mdry = Mpayload / mpayload
2nd GUESS Mdry = Mpayload + Mdry(mpower+ mPropDry + mstruct + melec + mCDH + mACS + mcomm + mtherm)
3rd GUESS, more refined Mdry = Mpayload + Mpower+ MPropDry + Mdry (mstruct + melec + mCDH + mACS + mcomm + mtherm)
Total wet mass, observatory mass Mlaunch = Mwet + payload adapter fitting Launch mass
ENAE 691 R.Farley NASA/GSFC
38
Mi known
M payload
M power
M PropDry
mj = unknown
+
m structure m ACS
m elec
m CDH m therm
Typical unknowns
m comm
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
39
Mi known
750
200
40
990
mj = unknown M dry
Feb 16 2005
+
0.20 0.06
0.07 0.03
0.01 0.04
0.41
990 ( 1 0.41 )
1678 kg
ENAE 691 R.Farley NASA/GSFC
40
cell
If the required orbital average power is not settled, then estimate with: Poa ~ PREQpayload + 0.5 (MDry Mpayload) watts, mass in kg
Power for payload instruments and associated electronics ~ 1 watt/kg * Mpayload
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
0.3
7 2 1.768. 10 . ALT
4 6.069. 10 . ALT
Sun syncronous
1 EtoD 0.9 0.54 Area Psa = P OA . 997. cell Area SA = AreaFactor. Area Psa
Required solar array projected area normal to sun, m2 Physical panel area, m2
Total solar array panel area considering energy balance going thru eclipse and geometric area factors, m2
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
42
Mass of honeycomb substrates: Msubstrates ~ 2.5 x ASA Msubstrates ~ 2.0 x ASA for aluminum panels for composite panels kg kg
Since multi junction cells usually go on composite substrates, and silicon cells went on aluminum substrates, it all comes out in the wash:
MPANELS ~ 5.85 x ASA Mass of solar array panels, electrical and structure: MPANELS = Melec + Msubstrates kg
kg
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
43
Battery mass, kg
Ni-Cads
Mpower = Mpanels + MSAD + MSAdeploy + Mbattery + MPSE Total power subsystem mass estimate, kg
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
44
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
45
Sun synchronous
Area SA =
1 EtoD 0.9 0.54 = 4.203 AF .P oa . 997 . cell 5.85 .Area SA = 24.6 0.06 .P oa = 40.5 0.04 .P oa = 27 0.33 .M panels = 8.1
= =
= M panels
M SAD
M SAdeploy
M battery
M PSE = 106.8
kg
46
ENAE 691
R.Farley NASA/GSFC
Isp is the amount of kick that the fuel has to offer per kg dMfuel/dt = Thrust / (g*Isp) kg per second
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
47
M fuel =
M dry . e
Or expressed as a ratio:
M fuel M dry
= e
V Isp.g
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
48
M fuel
M fuelDRAG
M fuelMANV
M PropDry
0.25. M fuel
Propulsion system mass, dry, kg tank, thrusters, lines, etc... Total spacecraft observatory mass with fuel, kg
M wet
M dry
M fuel
Remember, the dry mass estimate now includes the mass of the dry prop system components. This means iterating with a better dry mass estimate for a better fuel calculation.
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
49
Mfuel =
M dry . e
V Isp.g
1000 . e
1 = 86.7 kg
kg
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
Vibration Primmer
A vibrating structure can be thought of as the superposition of many mode shapes Each mode has a particular natural resonant frequency and distortion shape If the resonant frequencies are sufficiently separated, then the structural response can be estimated by treating each mode as a single-degree-of-freedom (sdof) system
3 usual flavors of vibration: Harmonic
Feb 16 2005
Random
ENAE 691 R.Farley NASA/GSFC
Impulsive
51
0.05 typical
52
cont
Gain function
Harmonic output acceleration = Harmonic input acceleration x T f is the applied input sinusoidal frequency, Hz fn is the natural resonant frequency Typical structural values for Q: 10 to 20 For small amplitude (jitter), or cryo temperatures: Q >100 Resonant Load Acceleration = input acceleration x Q
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
53
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
54
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
55
Input spectrum So described in power spectral density g2 per Hz Miles equation gives a statistical equivalent peak g load for a single degree of freedom system, 68% of the time (1). For 99.73% confidence (3), multiply by 3.
Mechanically conducted random and Acoustically conducted random
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
fn is the natural frequency of the system, Q is the resonant amplification, and So is the input acceleration power spectral density, g2/Hz
56
Quasi-Static loads
Linear and rotational accelerations + dynamic Dynamic Loads included in Quasi-Static: Harmonic vibration (sinusoidal) Random vibration (mostly of acoustic origin) Vibro-acoustic for light panels Dont forget, there are
Thermal loads
Limit loads do not have stress factors of safety incorporated yet
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
payload mass vs. c.g. height limitations for the launch vehicles payload adapter fitting
57
15Hz min
10Hz min
30Hz min
10Hz min
18Hz min
Beware 32Hz MECO-POGO
10Hz min
35Hz min
15Hz min
Note: the static and dynamic loads do not occur at the same time (usually)
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
58
Pegasus Loads
For Pegasus, quasi-static loads are equivalent to low frequency dynamic loads
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
59
To simplify, boil down to 3 load case combinations to analyze: Drop transient z ~ 6.5g lateral Stage burnout 10.5g axial, 1.7g lateral First lateral bending frequency > 20 Hz Aerodynamic pull-up 4.7g axial 3.5g lateral
R.Farley NASA/GSFC
Feb 16 2005
ENAE 691
60
Lcg
Reaction loads
The structural analyst will determine which load case produces the greatest combined axial-bending stress in the structure (I, A, mass and c.g. height)
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
61
Lateral load = Mwet*Nlateral*g = 2000*0.5*9.807 = 9807 N Moment = Lateral load * Lcg = 9807*1.5 = 14710.5 N-m Case b) load combination: Axial load = Mwet*Naxial*g = 2000*3.5*9.807 = 68649 N
Lateral load = Mwet*Nlateral*g = 2000*2.0*9.807 = 39228 N Moment = Lateral load * Lcg = 39228*1.5 = 58842 N-m
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
62
Titan
gload i 10
Proton Scout
This curve envelopes limit loads for small components under 500 kg Apply acceleration load separately in critical direction Add static 2.5 g in launch vehicle thrust direction
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
Simplified design curve for components on appendage-like structures under 80 Hz fundamental 63 frequency
Factors of safety for buckling (stability) elements ~ FS buckling = 1.4 (stability very dependent on boundary conditions.so watch out!)
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
64
For example, in many cases, the primary structure is some form of cylinder
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
65
or t = I / ( R3) or t = A / (2 R)
A = 2 R t
Determine the driving requirement resulting in the thickest wall t. Recalculate A and I with the chosen t.
Tapering thickness will drop frequency 5% to 12%, but greatly reduce structural mass 66
R.Farley NASA/GSFC
Max stress max = Paxialdes / A + (Plateraldes Lcg R) / I Margin of safety MS = {allowable / (FS x max)} 1 0 < MS acceptable For 7075-T6 aluminum, the yield allowable , allowable = 503 x 106 N/m2
With less stress the higher up, the more tapered the structure can be, saving mass
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
67
Compare critical stress to the maximum stress as calculated in the previous slide. Update the max stress if a new thickness is required.
Secondary structure (brackets, truss points, interfaces.) may equal or exceed the primary structure. An efficient structure, assume secondary structure = 1.0 x primary structure. A typical structure, assume 1.5. So, if the mass calculated for the un-optimized constant-wall thickness cylinder (primary structure) is MCYL, then the typical structure (primary + secondary): MSTRUCTURE ~ (2.0 to 3.5) x MCYL
This number can vary significantly
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
69
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
70
Anatomy of s/c
Heat of boxes radiating outward
Egg-crate extension
Instruments
EOS aqua
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
73
Composite Materials
Pros Lightweight (Strength to Weight ratio) Ability to tailor CTE High Strength Good conductivity in plane Thermal property variation possible (K1100) Low distortion due to zero CTE possible Ability to coat with substances (SiO) Electrical bonding a problem Some types of joints are more difficult to produce/design Fiber print through (whiskers) Upper temperature limit (Gel temperature) Moisture absorption / desorption / distortion Tooling more exotic, expensive/specialized tooling (higher rpms, diamond tipped) Cons Costly
74
Shrinkage ( D)
40
27 . 1
. 0.00113D
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
75
Solar array orbital average projected drag area for a tracking solar array that feathers during eclipse
ENAE 691 R.Farley NASA/GSFC
Feb 16 2005
76
Approximate maximum atmospheric density at the altitude ALT (km), kg / m3 good for 300 < ALT < 700 km Density factor, influenced by the 11 year solar maximum cycle (sin() argument in radians)
ALT)
M fuelDRAG
Feb 16 2005
If the mission requires altitude control, this is the approximate fuel mass for drag over the mission life
77
M fuelMANV
M dry . e
V ( Isp .g)
Or expressed as a ratio:
Feb 16 2005
M fuelMANV M dry
ENAE 691
V ( Isp .g)
R.Farley NASA/GSFC
78
Io
Dynamic system is critically damped Hinge point o Maximum Impact torque at lock-in, N-m d/dt can just be the velocity at time of impact if not critically damped
79
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
80
Rigid-body accelerations
Linear force F = m x a = m x g x Nfactor
N is the load factor in gs Low frequency sinusoidal below first natural frequency will produce near-static acceleration a = A x (2 f)2 where f is the driving frequency and A x = A sin(t) is the amplitude of sinusoidal motion
Q = I x alpha Fc = m x r x 2
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
81
Note: The maximum values for each usually occur at different times in the launch environment, luckily. The primary structure will have a different limit load than attached components. Solar arrays and other low area-density exposed components will react to vibro-acoustic loads.
Feb 16 2005 ENAE 691 R.Farley NASA/GSFC
82
dry mass
m = 1 kg
The axial frequency is sufficiently close to the driven dynamic frequency that we can consider the axial mode to be in resonance.
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
83
Length L Radius R
R y
Plateral
84
gs gs
gs
Feb 16 2005
ENAE 691
R.Farley NASA/GSFC
85