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ScienceDirect Procedia Engineering 185 (2017) 220 – 226
6th Russian-German Conference on Electric Propulsion and Their Application Shaping design layout of a combined insertion module with chemical acceleration and electric cruising units in creo elements/pro environment
K. V. Petrukhina a, A. S. Russkikh a,*, V. V.Salmin a, S. L. Safronov a a
Samara University, 34 Moskovskoe shosse, Samara 443086, Russia
Abstract The paper considers shaping the design layout of a combined insertion module, with chemical acceleration unit and electric propulsion cruising unit, intended to deliver payload to geostationary orbit, in the three dimensional design environment Creo elements/Pro. The result of the work are the design layout of an insertion module, including DM-03 chemical and electric propulsion cruising thrusters, satisfying the requirements set by the Angara A5 carrier and its nose cones. © TheAuthors. Authors.Published Publishedbyby Elsevier Ltd. This is an open access article under the CC BY-NC-ND license © 2017 The Elsevier B.V. (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the organizing committee of RGCEP – 2016. Peer-review under responsibility of the scientific committee of the 6th Russian-German Conference on Electric Propulsion and Their Application Keywords: combined insertion module; electric propulsion; chemical acceleration module; electric propulsion transport module; IT design layout shaping technologies.
1. Introduction Computer design technologies make their way into the process of spacecraft and rocket development, not only to automate the design process , but to change the very technology of design and development in principle. Computer-based design technologies are about forming a complete digital layout of the object, allowing a highquality product to be created in short time. Today these technologies are based on highly-developed intelligent design, engineering and manufacturing tools (CAD/CAM/CAE) and the project design management systems (PDM). One of such tools is the Creo Elements/Pro system, which is widely applied to development of new products in various areas including rocket and space technologies. This is a three-dimensional design tool that ensures continuity in the design of any product, no matter how sophisticated, embodying the latest 3D development instruments and the best achievements of numerous applied sciences and technologies.
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[email protected] © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the organizing committee of RGCEP – 2016.
1. Combined schemes of inserting spacecraft into remote orbits
1877-7058 © 2017 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the scientific committee of the 6th Russian-German Conference on Electric Propulsion and Their Application
doi:10.1016/j.proeng.2017.03.303
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The number of space transport operations keeps growing, which calls for improvement in their efficiency. The major efficiency criteria are the payload mass, insertion time, and insertion cost. Chemical propulsion systems (CPS) provide high torque, and are capable of inserting the payload in a very short time. However, at present they have no room for improvement in terms of efficiency. The alternative is electric propulsion thrusters (EPT), which are capable of delivering higher payload, but at a longer time. At this stage, EPT cannot replace CPS, because they do not have enough torque, but by a combination of these two types of propulsion we can obtain a significant increase in efficiency, including cost-efficiency. A combined propulsion system uses a chemical acceleration module at the first stage, to insert the spacecraft into an intermediate elliptic orbit, and at the second stage adjusts the orbit to the target orbit by means of electric propulsion. The target orbit can be any orbit sufficiently remote from the initial orbit, with considerable differences from it in terms of semi-major axis, inclination and eccentricity - for example, a geostationary orbit. This scheme was used for insertion of the Express series spacecraft [1]. Consequently, the combined insertion module (CIM) consists of a chemical acceleration unit (CAU) and electric propulsion cruising unit (EPCU), which are separated in flight. 2. Stages of forming the design layout of the combined insertion module During the first stage, the developers form the base data package, determining the parameters of initial, intermediate and target orbit, insertion devices, chemical and electric propulsion modules and the power unit. The second stage is dedicated to optimization of the ballistic scheme of the transfer, and computation of the combined insertion module design parameters. At this stage, such parameters as transfer time, the passage through shadow and radiation belts, characteristic velocity, as well as the mass, dimensions and setup of the insertion module, are computed. At the third stage the design layout of the insertion module emerges from results obtained on the previous stages. The methodology for optimization of ballistic and design parameters of a transfer with combined propulsion system is described in [2]. 3. Base data for computer modeling This paper considers a transfer to a geostationary orbit (GSO) with the help of the new Russian heavy launch vehicle Angara A5. This is a module type rocket, developed from two all-around rocked modules. It can consist of five all-around modules. The upper stages can be Breeze-M and DM-03 acceleration modules, as well as the oxygenhydrogen thruster KVTK, which can be used in a combined propulsion module. The calculations below were carried out for DM-03. Table 1. Characteristics of Angara A5 launch vehicle with DM-03 acceleration module
Parameter
Value
Length, m.
55.1
Launch weight, kg.
773000
Nose cone length, m.
13.2-11.8
Nose cone diameter, m
4.35-5.1
Payload mass (for 200 km orbit, launch from Vostochny), kg.
24500
Payload mass (for geostationary orbit, launch from Vostochny), kg
3900
The DM-03 acceleration module is shown on Fig. 1. It is used for a combined propulsion system without any changes.
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1.equipment capsule . 2 equipment frame. 3. heat exchanger pipes. 4 - upper adapter; 5 - oxidizer tank; 6 - middle adapter; 7 - fuel tank; 8 - combined launch, orientation and stabilization unit; 9 - lower adapter; 10 - cruising thruster. Fig. 1. DM-03 acceleration module.
A set of design parameters describe the initial design layout of the electric propulsion unit, and then the combined propulsion module. For this, it is necessary to determine the type, setup, instruments and other elements of the EPCT. In general, an electric propulsion module can feature the following units: 1. Thruster unit: - electric propulsion thrusters; - fuel supply and storage system; - connectors. 2. Orientation and stabilization unit. 3. Electric power supply system: - solar panels; - accumulating batteries. 4. Body: - frame; - solar panel frames; - fixation elements. 5. Undocking system. 6. On-board cable network. 7. Thermal control system. 8. Command and control module. 9. Electric automation module. 10. On-board radio complex. 11. Antennae and feeder system. 12. Telemetry system [3]. The main elements are the thruster module, propellant storage and supply module, orientation and stabilization system, solar panels and their framework; the main frame. These are the element that determine the design layout, mass and geometrical parameters of the EPCU. The EPCU is mounted on a carrier frame covered with cellular panels. The thruster is selected according to its basic parameters, such as torque, power and lifetime. In Russia, stationary plasma thrusters designed by Fakel R&D Bureau are very popular. Of these, the SPD-140 has the best characteristics. For the stabilization and orientation systems, as a rule, mono-component electric propulsion systems working on hydrazine are used.
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The propellant supply and storage system (the propellant is xenon, liquefied under 40MPa pressure) ensures reliable storage and supply of the propellant to the thrusters. When the propellant is in the gas phase, it consists of fuel tanks, pipelines, various valves and reducers, and other elements. The best storage for xenon are specialized tanks developed by FSUE RDIME and OAO UNIIKM, which have passed all flight tests and performed well in outer space. They are composite high-pressure vessels that consist of thinwalled hermetic metal liners and heavy-duty shells of strong polymeric material. [4] The electric propulsion system receives electric power from nickel-hydrogen battery modules and a solar power system. The solar panels made by OAO Saturn are used not only on all near-Earth orbits, but also in deep space. Currently the most efficient solar panels are the arsenic-gallium photo converting type. Their efficiency coefficient is 28%, and relative power is 250-300 volt per square meter. Their maximum temperature of operation is +150 оС, in contrast to only +70 оС of the silicon panels. This increases the potential of focusing light on GaAs heterophotoconverter. In addition, the GaAs solar panels are much more resistant to proton flows and high-energy electrons than silicon panels, due to GaAs higher level of light absorption [5]. The thermal control system, as well as the frame elements of the spacecraft, ensures a proper temperature for the operation of the various design elements, equipment and modules of the electric propulsion unit, both in flight and during on-ground preparation. To transfer heat efficiently across the body panels and to increase their thermal conductivity rate, heat conductive elements and heat transfer pipes are used. Heat conducting elements and pipes are mounted inside the body panels. Surface electric heaters ensure the required minimal temperature for panels and various elements of the spacecraft design, including thruster mounts, xenon storage tanks, etc. Heat radiators, mounted on the outside of the body panels and framework of the spacecraft, dissipate the extra heat generated by the on-board equipment. Based on the methodology described in [2], the ballistic design parameters were calculated. The base data for the calculations and the results obtained are presented in Tables 2, 3, and 4. Table 2. Base data
Parameter Spacecraft weight at launch, kg Propellant mass for CPU, kg CPU end (dry) mass, kg. CPU torque, N CPU Specific Impulse, s. Torque of 1 EP unit (SPD-140), mN EP specific impulse, s. Power consumption of 1 EP thruster, kWt Weight of 1 EP thruster, kg. Number of operating EP thrusters Specific mass of the EP unit, kg/kWt Specific mass of propellant storage and supply system. Specific mass of spacecraft body Height of initial orbit, km Inclination of initial orbit, degrees. Semi-major axis of intermediate orbit, km Eccentricity of intermediate orbit
Value 24500 18991 3377 50000 378 280 2600 6 8.4 12 10 0.07 0.15 200 51.5 16000 0.5
Table 3. Ballistic parameters of the transfer
Parameter Transfer time, days.. Propulsion time, days. . Time in Earth's radiation belts, days. Time in Earth's shadow, days. Orbit time, hours. Number of coils. Characteristic velocity, km/s.
Value 192 192 0 0,74 23.934 318 5.728
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Parameter Spacecraft mass at intermediate orbit, kg. Electric power module mass, kg. EP system mass, kg. Chemical propulsion unit mass, kg. Propellant mass for EP system, kg. Body mass, kg. Payload mass, kg. Full torque, mN. Initial acceleration, mm/s2. Area of solar panels, m2.
Value 10863 720 100.8 152.9 2185 1629.5 6154.3 3360 0.309 261
4. Shaping the design layout of a combined insertion module The obtained data allows to shape the design layout of the combined insertion module in the environment of automated design system Creo Elements/Pro. Creo Elements/Pro is designed to be used by the developer from the very beginning of the work on the object - from the moment of determining the elements of design and their characteristics. A cascade menu ensures logical choice and installation of most pre-chosen options. Full help on executed functions and tips is available at any time. This makes Creo Elements/Pro easy to use even for unprepared designers. The system allows diagrammed geometry to be performed right on the hard-body model, which makes it possible to add objects and features to the design. The system is based on a single data structure, which allows changes to be made in the structure itself. Therefore, changes made at any moment of development are automatically extended to all finished stages of the design process, ensuring continuity of design. Creo Elements/Pro modelling is based on features such as edges, shoulders, rounding, shells, etc. and can recreate geometry of any complexity. Apart from data on their location and connection to other objects, features also contain non-geometric data, such as manufacturing methods and associated costs. There is no need to attach features to a system of coordinates, because these are directly connected to existing geometry. As a result, all changes are made easily and quickly, and in full accordance with the designer's ideas. In Creo Elements/Pro environment the components are assembled by such operations as "join", "level", "insert", "orient", etc. It can create assemblies of any complexity. The components have a "memory" of their position, and the changes of either in form or in placement of any part are extended to other characteristics. A part can be designed directly during the assembly process, determining its shape to fit the area or according to existing parts, and if the shape or location of adjoining parts are changed, the form and placement of the designed part are automatically renewed. Hard-body modeling in Creo Elements/Pro is based on edgeless double precision technology, which ensures high precision in representation of geometry, mass and verification of various clearances and jams. The system is fully associated, which presents great opportunities for introduction of any changes, ensuring synchronous design and technological processes. The parametric data base tool makes it possible to control both processes in synchrony and run any tests [6]. The design layout of the combined insertion module is represented in Fig. 3 and 4. The octangular frame is made of hollow pipes and covered on all sides with cellular panels. The outside of the panels houses various sensors (solar, stellar, etc.), antennae and feeders, heat radiators, satellite navigation module, and six EP orientation and stabilization thrusters. The inner side of the panels is for fitting the instruments. The bottom panel houses the cruising EP system, consisting of eight operating and four spare thrusters. There also are eight gas thrusters that stabilize the spacecraft in case a problem while undocking the EPCU from DM-03 results in a spin, and the pneumatic network supplying propellant from tanks to thrusters. The tanks themselves are located inside the spacecraft and are fixed by two conical mounts. The mounts for the solar panel positioning system are fixed on the top of the four side frames. The EPCU is docked to the DM-03 acceleration module with eight explosive bolts that ensure separation of the DM-03 module after it finishes its operation. The design layout of the combined insertion module is shown in Fig. 2.
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1 - electric propulsion transfer module; 2 - DM-03 acceleration module Fig. 2. Design layout of combined insertion module
1 - solar sensor; 2 - solar panel positioning unit; 3 - heat radiator; 4 - satellite navigation module; 5 - gas thruster; 6 - cruising electric propulsion unit; 7 - antenna Fig. 3. Design layout of electric propulsion cruising unit (view from bottom, solar panels not shown)
1 - main frame; 2 - xenon storage tanks; 3 - stellar sensor; 4 - cellular panels; 5 - antenna Fig. 4. Design layout of electric propulsion cruising unit (view from top, solar panels and upper panels are not shown)
Fig. 5 and 6 show the geometric dimensions of the combined insertion module, to show the overall size of the unit, its major parts, and the payload areas. In the main view, A stands for the plane where the insertion module is joined to the head cone. The images demonstrate that it is possible to use the insertion module with the Angara-A5 launch vehicle and the head cones that come with it.
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Fig. 5. Geometrical dimensions of the combined insertion module (main view and view from top, millimeters)
Fig. 6. The EP cruising module with solar panels deployed
5. Conclusions The ballistic design parameters of a transfer to geostationary orbit were calculated and the results obtained used to create the design layout of a combined insertion module in a Creo Elements/Pro environment. Calculations show that this insertion module allows the payload to be increase by 60%, as compared to traditional insertion devices, meaning that it is possible to insert two satellites of the "Express" class instead of one. However, the delivery time increases to as long as 192 days. Computer modelling supports the theoretical possibility of creating such a module [7-9] to be used with existing launch vehicles, head cones and acceleration modules. References [1] Prospects for increasing efficiency of "Express 1000N" and "Express 2000" platform communication satellites In Russian. http://omyconf.com/uploads/conference/43feaeeecd7b2fe2ae2e26d917b6477d/material/popov.pdf [2] Petrukhina K. V., Salmin V.V. (2010) "Optimization of ballistic schemes of transfers between noncoplanar orbits with combination of highthrust and low-thrust propulsion units". In Russian. Bulletin of Samara Center of Russian Academy of Science, vol. 12 # 4 pp 186-201 [3] Malyshev, G. V., Kulkov, V. M.,. Egorov, Yu.G. (2006) "Using electric propulsion for insertion, orbit correction, and support of satellite constellations". In Russian. Polyot, #7, pp 82-88. [4] Arkhipov, Yu. S., Buldashev, S.A., Dudin, A. I., Ermakov, A. N. 0000. Experiment in creating composite tanks for "Express" type spacecraft. (In Russian)FGUP "NII Mashinostroyenia", Nizhnaya Salda. pp 1-4 [5] Solar Panels. http://www.saturn-kuban.ru/solar_battery.html [6] EPD. Electronic Product Definition – full electronic description of a device www.rsce.ru [7] V.K. Semenichev, E.I. Kurkin, E.V. Semenichev, A.A. Danilova, G.A. Fisun, E.I. Kasatkina, Non-renewable Recourses Life Cycles Modeling Aspects, Procedia Computer Science, Volume 65, 2015, Pages 872-879, ISSN 1877-0509 [8] Borgest N., Korovin M., Gromov A., Gromov A. The concept of automation in conventional systems creation applied to the preliminary aircraft design // Advances in Intelligent Systems and Computing, 2015. Vol. 342. P. 147-156 [9] I. Gorbunova, O. Starinova and S. Olga, "Complex simulation of the solar sail spacecraft," 2013 6th International Conference on Recent Advances in Space Technologies (RAST), Istanbul, 2013, pp. 285-290.
