Launching to the Moon, Mars, and Beyond

The U.S. Vision for Space Exploration, announced in 2004, calls on NASA to finish constructing the International Space Station, retire the Space Shuttle, and build the new spacecraft needed to return to the Moon and go on the Mars. By exploring space, America continues the tradition of great nations who mastered the Earth, air, and sea, and who then enjoyed the benefits of increased commerce and technological advances. The progress being made today is part of the next chapter in America's history of leadership in space. In order to reach the Moon and Mars within the planned timeline and also within the allowable budget, NASA is building upon the best of proven space transportation systems. Journeys to the Moon and Mars will require a variety of vehicles, including the Ares I Crew Launch Vehicle, the Ares V Cargo Launch Vehicle, the Orion Crew Exploration Vehicle, and the Lunar Surface Access Module. What America learns in reaching for the Moon will teach astronauts how to prepare for the first human footprints on Mars. While robotic science may reveal information about the nature of hydrogen on the Moon, it will most likely tale a human being with a rock hammer to find the real truth about the presence of water, a precious natural resource that opens many possibilities for explorers. In this way, the combination of astronauts using a variety of tools and machines provides a special synergy that will vastly improve our understanding of Earth's cosmic neighborhood

NASA Crew and Cargo Launch Vehicle Development Approach Builds on Lessons from Past and Present Missions

The United States (US) Vision for Space Exploration, announced in January 2004, outlines the National Aeronautics and Space Administration's (NASA) strategic goals and objectives, including retiring the Space Shuttle and replacing it with new space transportation systems for missions to the Moon, Mars, and beyond. The Crew Exploration Vehicle (CEV) that the new human-rated Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the International Space Station (ISS) Toward the end of the next decade, a heavy-lift Cargo Launch Vehicle (CaLV) will deliver the Earth Departure Stage (EDS) carrying the Lunar Surface Access Module (LSAM) to low-Earth orbit (LEO), where it will rendezvous with the CEV launched on the CLV and return astronauts to the Moon for the first time in over 30 years. This paper outlines how NASA is building these new space transportation systems on a foundation of legacy technical and management knowledge, using extensive experience gained from past and ongoing launch vehicle programs to maximize its design and development approach, with the objective of reducing total life cycle costs through operational efficiencies such as hardware commonality. For example, the CLV in-line configuration is composed of a 5-segment Reusable Solid Rocket Booster (RSRB), which is an upgrade of the current Space Shuttle 4- segment RSRB, and a new upper stage powered by the liquid oxygen/liquid hydrogen (LOX/LH2) J-2X engine, which is an evolution of the J-2 engine that powered the Apollo Program s Saturn V second and third stages in the 1960s and 1970s. The CaLV configuration consists of a propulsion system composed of two 5-segment RSRBs and a 33- foot core stage that will provide the LOX/LED needed for five commercially available RS-68 main engines. The J-2X also will power the EDS. The Exploration Launch Projects, managed by the Exploration Launch Office located at NASA's Marshall Space Flight Center, is leading the design, development, testing, and operations planning for these new space transportation systems. Utilizing a foundation of heritage hardware and management lessons learned mitigates both technical and programmatic risk. Project engineers and managers work closely with the Space Shuttle Program to transition hardware, infrastructure, and workforce assets to the new launch systems, leveraging a wealth of knowledge from Shuffle operations. In addition, NASA and its industry partners have tapped into valuable Apollo databases and are applying corporate wisdom conveyed firsthand by Apollo-era veterans of America s original Moon missions. Learning from its successes and failures, NASA employs rigorous systems engineering and systems management processes and principles in a disciplined, integrated fashion to further improve the probability of mission success

Building Operations Efficiencies into NASA's Crew Launch Vehicle Design

The U.S. Vision for Space Exploration guides NASA's challenging missions of technological innovation and scientific investigation. With the Agency's commitment to complete the International Space Station (ISS) and to retire the Space Shuttle by 2010, the NASA Administrator commissioned the Exploration Systems Architecture Study (ESAS) in mid 2005 to analyze options for a safer, simpler, more cost efficient launch system that could deliver timely human-rated space transportation capabilities. NASA's finite resources yield discoveries with infinite possibilities. As the Agency begins the process of replacing the Shuttle with new launch vehicles destined for missions beyond low-Earth orbit to the Moon and Mars, NASA is designing the follow-on crew and cargo systems for maximum operational efficiencies. This mandate is imperative to reduce the $4.5 billion NASA spends on space transportation each year. This paper gives top-level details of how the follow-on Crew Launch Vehicle (CLV) is being designed for reduced lifecycle costs as a primary catalyst for the expansion of future frontiers

A New Heavy-Lift Capability for Space Exploration: NASA's Ares V Cargo Launch Vehicle

The U.S. vision for space exploration is to: a) Implement a sustained and affordable human and robotic program to explore the solar system and beyond b) Extend human presence across the solar system, starting with a human return to the Moon by the year 2020, in preparation for the human exploration of Mars and other destinations c) Develop the innovative technologies, knowledge, and infrastructures both to explore and to support decisions about the destinations for human exploration, and d) Promote international and commercial participation in exploration

NASA Crew Launch Vehicle Approach Builds on Lessons from Past and Present Missions

The United States Vision for Space Exploration, announced in January 2004, outlines the National Aeronautics and Space Administration's (NASA) strategic goals and objectives, including retiring the Space Shuttle and replacing it with a new human-rated system suitable for missions to the Moon and Mars. The Crew Exploration Vehicle (CEV) that the new Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the International Space Station and be capable of carrying crews back to lunar orbit and of supporting missions to Mars orbit. NASA is using its extensive experience gained from past and ongoing launch vehicle programs to maximize the CLV system design approach, with the objective of reducing total lifecycle costs through operational efficiencies. To provide in-depth data for selecting this follow-on launch vehicle, the Exploration Systems Architecture Study was conducted during the summer of 2005, following the confirmation of the new NASA Administrator. A team of aerospace subject matter experts used technical, budget, and schedule objectives to analyze a number of potential launch systems, with a focus on human rating for exploration missions. The results showed that a variant of the Space Shuttle, utilizing the reusable Solid Rocket Booster as the first stage, along with a new upper stage that uses a derivative of the RS-25 Space Shuttle Main Engine to deliver 25 metric tons to low-Earth orbit, was the best choice to reduce the risks associated with fielding a new system in a timely manner. The CLV Project, managed by the Exploration Launch Office located at NASA's Marshall Space Flight Center, is leading the design, development, testing, and operation of this new human-rated system. The CLV Project works closely with the Space Shuttle Program to transition hardware, infrastructure, and workforce assets to the new launch system . leveraging a wealth of lessons learned from Shuttle operations. The CL V is being designed to reduce costs through a number of methods, ranging from validating requirements to conducting trades studies against the concept design. Innovations such as automated processing will build on lessons learned from the Shuttle, other launch systems, Department of Defense operations experience, and subscale flight tests such as the Delta Clipper-Experimental Advanced (DCXA) vehicle operations that utilized minimal touch labor, automated cryogen ic propellant loading , and an 8-hour turnaround for a cryogenic propulsion system. For the CLV, the results of hazard analyses are contributing to an integrated vehicle health monitoring system that will troubleshoot anomalies and determine which ones can be solved without human intervention. Such advances will help streamline the mission operations process for pilots and ground controllers alike. In fiscal year 2005, NASA invested approximately $4.5 billion of its$16 bill ion budget on the Space Shuttle. The ultimate goal of the CLV Project is to deliver a safe, reliable system designed to minimize lifecycle costs so that NASA's budget can be invested in missions of scientific discovery. Lessons learned from developing the CLV will be applied to the growth path for future systems, including a heavy lift launch vehicle

Ares I Crew Launch Vehicle Project: Forward Plan to Preliminary Design Review

The Exploration Launch Projects Office, located at NASA's Marshall Space Flight Center, conducted the Ares I Crew Launch Vehicle System Requirements Review (SRR) at the end of 2006, a mere year after the project team was assembled. In Ares' first year, extensive trade studies and evaluations were conducted to refine the design initially recommended by the Exploration Systems Architecture Study, conceptual designs were analyzed for fitness, and the contractual framework was assembled to enable a development effort unparalleled in American space flight since the Space Shuttle. Now, the project turns its focus to the Preliminary Design Review (PDR), scheduled for 2008. Taking into consideration the findings of the SRR, the design of the Ares I is being tightened and refined to meet the operability, reliability, and affordability goals outlined by the Constellation Program. As directed in NASA Procedure and Regulation (NPR) 7123, NASA Systems Engineering Procedural Requirements, the Ares I SRR examined "the functional and performance requirements defined for the system and the preliminary program or project plan and ensures that the requirements and the selected concept will satisfy the mission." The SRR was conducted to ensure the system- and element-level design and interface requirements are defined prior to proceeding into the project's design phase. The Exploration Launch Projects Control Board convened on December 19,2006, and accepted the findings of the SRR and the go-forward plan proceeding to PDR. Based upon these findings, the Ares project believes that operability must drive the vehicle's design, and that a number of design challenges, including system mass and reliability, must be addressed as part of the progress to PDR

Getting to First Flight: Equipping Space Engineers to Break the Start-Stop-Restart Cycle

The National Aeronautics and Space Administration s (NASA s) history is built on a foundation of can-do strength, while pointing to the Saturn/Apollo Moon missions in the 1960s and 1970s as its apex a sentiment that often overshadows the potential that lies ahead. The chronicle of America s civil space agenda is scattered with programs that got off to good starts with adequate resources and vocal political support but that never made it past a certain milestone review, General Accountability Office report, or Congressional budget appropriation. Over the decades since the fielding of the Space Shuttle in the early 1980s, a start-stop-restart cycle has intervened due to many forces. Despite this impediment, the workforce has delivered engineering feats such as the International Space Station and numerous Shuttle and science missions, which reflect a trend in the early days of the Exploration Age that called for massive infrastructure and matching capital allocations. In the new millennium, the aerospace industry must respond to transforming economic climates, the public will, national agendas, and international possibilities relative to scientific exploration beyond Earth s orbit. Two pressing issues - workforce transition and mission success - are intertwined. As this paper will address, U.S. aerospace must confront related workforce development and industrial base issues head on to take space exploration to the next level. This paper also will formulate specific strategies to equip space engineers to move beyond the seemingly constant start-stop-restart mentality to plan and execute flight projects that actually fly

Product Lifecycle Management and the Quest for Sustainable Space Explorations

Product Lifecycle Management (PLM) is an outcome of lean thinking to eliminate waste and increase productivity. PLM is inextricably tied to the systems engineering business philosophy, coupled with a methodology by which personnel, processes and practices, and information technology combine to form an architecture platform for product design, development, manufacturing, operations, and decommissioning. In this model, which is being implemented by the Engineering Directorate at the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center, total lifecycle costs are important variables for critical decision-making. With the ultimate goal to deliver quality products that meet or exceed requirements on time and within budget, PLM is a powerful concept to shape everything from engineering trade studies and testing goals, to integrated vehicle operations and retirement scenarios. This paper will demonstrate how the Engineering Directorate is implementing PLM as part of an overall strategy to deliver safe, reliable, and affordable space exploration solutions. It has been 30 years since the United States fielded the Space Shuttle. The next generation space transportation system requires a paradigm shift such that digital tools and knowledge management, which are central elements of PLM, are used consistently to maximum effect. The outcome is a better use of scarce resources, along with more focus on stakeholder and customer requirements, as a new portfolio of enabling tools becomes second nature to the workforce. This paper will use the design and manufacturing processes, which have transitioned to digital-based activities, to show how PLM supports the comprehensive systems engineering and integration function. It also will go through a launch countdown scenario where an anomaly is detected to show how the virtual vehicle created from paperless processes will help solve technical challenges and improve the likelihood of launching on schedule, with less hands-on labor needed for processing and troubleshooting

Product Lifecycle Management and the Quest for Sustainable Space Exploration Solutions

Product Lifecycle Management (PLM) is an outcome of lean thinking to eliminate waste and increase productivity. PLM is inextricably tied to the systems engineering business philosophy, coupled with a methodology by which personnel, processes and practices, and information technology combine to form an architecture platform for product design, development, manufacturing, operations, and decommissioning. In this model, which is being implemented by the Engineering Directorate at the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center, total lifecycle costs are important variables for critical decisionmaking. With the ultimate goal to deliver quality products that meet or exceed requirements on time and within budget, PLM is a powerful tool to shape everything from engineering trade studies and testing goals, to integrated vehicle operations and retirement scenarios. This paper will demonstrate how the Engineering Directorate is implementing PLM as part of an overall strategy to deliver safe, reliable, and affordable space exploration solutions. It has been 30 years since the United States fielded the Space Shuttle. The next generation space transportation system requires a paradigm shift such that digital tools and knowledge management, which are central elements of PLM, are used consistently to maximum effect. The outcome is a better use of scarce resources, along with more focus on stakeholder and customer requirements, as a new portfolio of enabling tools becomes second nature to the workforce. This paper will use the design and manufacturing processes, which have transitioned to digital-based activities, to show how PLM supports the comprehensive systems engineering and integration function. It also will go through a launch countdown scenario where an anomaly is detected to show how the virtual vehicle created from paperless processes will help solve technical challenges and improve the likelihood of launching on schedule, with less hands-on labor needed for processing and troubleshooting. Sustainable space exploration solutions demand that all lifecycle phases be optimized. Adopting PLM, which has been used by the automotive industry for many years, for aerospace applications provides a foundation for strong, disciplined systems engineering and accountable return on investment by making lifecycle considerations variables in an iterative decision-making process. This paper combines the perspectives of the founding father of PLM, along with the experience of Engineering leaders who are implementing these processes and practices real-time. As the nation moves from an industrial-based society to one where information is a valued commodity, future NASA programs and projects will benefit from the experience being gained today for the exploration missions of tomorrow

Ares Launch Vehicles Development Awakens Historic Test Stands at NASA's Marshall Space Flight Center

This paper chronicles the rebirth of two national rocket testing assets located at NASA's Marshall Space Flight Center: the Dynamic Test Stand (also known as the Ground Vibration Test Stand) and the Static Test Stand (also known as the Main Propulsion Test Stand). It will touch on the historical significance of these special facilities, while introducing the requirements driving modifications for testing a new generation space transportation system, which is set to come on line after the Space Shuttle is retired in 2010. In many ways, America's journey to explore the Moon begins at the Marshall Center, which is developing the Ares I crew launch vehicle and the Ares V cargo launch vehicle, along with managing the Lunar Precursor Robotic Program and leading the Lunar Lander descent stage work, among other Constellation Program assignments. An important component of this work is housed in Marshall's Engineering Directorate, which manages more than 40 facilities capable of a full spectrum of rocket and space transportation technology testing - from small components to full-up engine systems. The engineers and technicians who operate these test facilities have more than a thousand years of combined experience in this highly specialized field. Marshall has one of the few government test groups in the United States with responsibility for the overall performance of a test program from conception to completion. The Test Laboratory has facilities dating back to the early 1960s, when the test stands needed for the Apollo Program and other scientific endeavors were commissioned and built along the Marshall Center's southern boundary, with logistics access by air, railroad, and barge or boat on the Tennessee River. NASA and its industry partners are designing and developing a new human-rated system based on the requirements for safe, reliable, and cost-effective transportation solutions. Given below are summaries of the Dynamic Test Stand and the Static Test Stand capabilities, along with an introduction to the new missions that these sleeping giants will be fulfilling as NASA readies the Ares I for service in the 2015 timeframe, and plans the development work for fielding the Ares V late next decade (fig. 1). Validating modern computer design models and techniques requires the sorts of data that can only be generated by these one-of-a-kind facilities