Optimization Approaches Under Uncertainty for Hybrid Rocket Engines

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Optimal Design of Electrically Fed Hybrid Mars Ascent Vehicle

The optimal design of the propulsion system for a potential Mars Ascent Vehicle is analyzed, in the context of the Mars Sample Return Mission. The Mars Ascent Vehicle has to perform an initial ascent phase from the surface and then circularize into a 170 km orbit. A two-stage launcher is taken into account: the same hybrid rocket engine is considered for both stages in order to limit the development costs. A cluster of two, three or four engines is employed in the first stage, whereas a single engine is always used in the second stage. Concerning the feeding system, three alternatives are taken into consideration, namely a blow down, a regulated and an electric turbo-pump feed system. The latter employs an electric motor to drive the oxidizer turbopump, whereas the power is supplied to the motor by lithium batteries. All the design options resulted in viable Mars Ascent Vehicle configurations (payloads are in the range of 70–100 kg), making the hybrid alternative worth considering for the sample return mission. The use of an electric turbo-pump feed system determines the highest vehicle performance with an estimated 10–25% payload gain with respect to gas-pressure feed systems

Low-Order Models for Low-Frequency Combustion Instability in Hybrid Rocket Engines

A low-order model for a hybrid rocket engine is proposed to investigate low-frequency combustion instabilities. The present work is based on a one-way coupling between a one-dimensional thermal model to evaluate the unsteady regression rate and a zero-dimensional model which imposes mass conservation inside the rocket chamber. In this way, it is possible to estimate the unsteady pressure level inside the rocket chamber and predict the amplitude of the oscillations. Two different approaches are compared. In the first approach, the Oxidizer-Fuel (OF) ratio is directly computed from the ratio between the fuel and oxidizer mass flow rates. In this way the OF ratio strongly depends on the regression rate oscillations and, as a consequence, the pressure shows large fluctuations. An alternative approach has been investigated by computing the OF ratio from the fuel and oxidizer istantaneous densities. The two approaches are compared on a representative test case

Emission-Driven Hybrid Rocket Engine Optimization for Small Launchers

Hybrid rocket engines are a green alternative to solid rocket motors and may represent a low-cost alternative to kerosene fueled rockets, while granting performance and control features similar to that of typical storable liquid rocket engines. In this work, the design of a three-stage hybrid launcher is optimized by means of a coupled procedure: an evolutionary algorithm optimizes the engine design, whereas an indirect optimization method optimizes the corresponding ascent trajectory. The trajectory integration also provides the vertical emission profiles required for the evaluation of the environmental impact of the launch. The propellants are a paraffin-based wax and liquid oxygen. The vehicle is launched from the ground and uses an electric turbo pump feed system. The initial mass is given (5000 kg) and the insertion of the payload into a 600-km circular, and polar orbit is considered as a reference mission. Clusters of similar hybrid rocket engines, with only few differences, are employed in all stages to reduce the development and operational costs of the launcher. Optimization is carried out with the aim of maximizing the payload mass and then minimizing the overall environmental impact of the launch. The results show that satisfactory performance is achievable also considering rocket polluting emissions: the carbon footprint of the launch can be reduced by one fourth at the cost of a 5-kg payload mass reduction

Viability of an Electrically Driven Pump-Fed Hybrid Rocket for Small Launcher Upper Stages

An electrically driven pump-fed cycle for a hybrid rocket engine is proposed and compared to a simpler gas-pressurized feed system. A liquid-oxygen/paraffin-based fuel hybrid rocket engine which powers the third stage of a Vega-like launcher is considered. Third-stage ignition conditions are assigned, and engine design and payload mass are defined by a proper set of parameters. Uncertainties in the classical regression rate correlation coefficients are taken into account and robust design optimization is carried out with an approach based on an epsilon-constrained evolutionary algorithm. A mission-specific objective function, which takes into account both the payload mass and the ability of the rocket to reach the required final orbit despite uncertainties, is determined by an indirect trajectory optimization approach. The target orbit is a 700 km altitude polar orbit. Results show that electrically driven pump-fed cycle is a viable option for the replacement of the conventional gas-pressurized feed system. Robustness in the design is granted and a remarkable payload gain is achieved, using both present and advanced technologies for electrical systems

Hybrid Rocket Engine Design Optimization at Politecnico di Torino: A Review

Optimization of Hybrid Rocket Engines at Politecnico di Torino began in the 1990s. A comprehensive review of the related research activities carried out in the last three decades is here presented. After a brief introduction that retraces driving motivations and the most significant steps of the research path, the more relevant aspects of analysis, modeling and achieved results are illustrated. First, criteria for the propulsion system preliminary design choices (namely the propellant combination, the feed system and the grain design) are summarized and the engine modeling is presented. Then, the authors describe the in-house tools that have been developed and used for coupled trajectory and propulsion system design optimization. Both deterministic and robust-based approaches are presented. The applications that the authors analyzed over the years, starting from simpler hybrid powered sounding rocket to more complex multi-stage launchers, are then presented. Finally, authors’ conclusive remarks on the work done and their future perspective in the context of the optimization of hybrid rocket propulsion systems are reported

Multi-objective Optimization of Electric Pumps for Hybrid Rocket Engines

A multi-objective optimization of an electric pump for hybrid rockets is carried out through an evolutionary algorithm. The pump is modeled by means of a meanline flow method. For given values of required head and flow rate, some of the pump design parameters are varied to minimize the power and the torque to be delivered by the motor. The two minima do not coincide because of the dependence of pump power losses on shaft speed for different geometries; Pareto-optimal solutions are found near the upper bound of the chosen speed rang

Emission-Driven Hybrid Rocket Engine Optimization for Small Launchers

Hybrid rocket engines are a green alternative to solid rocket motors and may represent a low-cost alternative to kerosene fueled rockets, while granting performance and control features similar to that of typical storable liquid rocket engines. In this work, the design of a three-stage hybrid launcher is optimized by means of a coupled procedure: an evolutionary algorithm optimizes the engine design, whereas an indirect optimization method optimizes the corresponding ascent trajectory. The trajectory integration also provides the vertical emission profiles required for the evaluation of the environmental impact of the launch. The propellants are a paraffin-based wax and liquid oxygen. The vehicle is launched from the ground and uses an electric turbo pump feed system. The initial mass is given (5000 kg) and the insertion of the payload into a 600-km circular, and polar orbit is considered as a reference mission. Clusters of similar hybrid rocket engines, with only few differences, are employed in all stages to reduce the development and operational costs of the launcher. Optimization is carried out with the aim of maximizing the payload mass and then minimizing the overall environmental impact of the launch. The results show that satisfactory performance is achievable also considering rocket polluting emissions: the carbon footprint of the launch can be reduced by one fourth at the cost of a 5-kg payload mass reduction