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Deliver 5kg item to ISS 24 hour launch lead time Vehicle must be launched from below or inside carrier aircraft Propellants cannot be toxic. Upper stage must have good orbital insertion accuracy Vehicle must use off-the-shelf rocket motors First priority is to deliver takeoff mass to aircraft team.
Calculates:
DV produced by each stage upper stage structural mass booster takeoff mass Max G-Force during launch
Input Variables:
Stage Specifications Payload Mass
Booster Calculator
mp1 3923 me1 416 mp2 1286 me2 98 mp3 me3 mpl 310 80.20679 T1 40 170000 T2 80000 T3 33300 Isp1 260 Isp2 293 Isp3 330 mb01 m01 mb02 m02 mb03 m03 dv1 dv2 dv3 delta v 2230.207 6153.207 528.2068 1814.207 120.2068 430.2068 2011.145 3093.411 3832.083 8936.64 R1 R2 R3 2.816297 4.495047 7.890381 1st Stage: ATK Orion 50XL 2nd Stage: ATK Star 31 3rd Stage: SpaceX Kestrel 2 (Would like lighter, slightly smaller engine with similar ISP, but sufficient) (Pump fed would reduce weight of upper stage structure, but add compexity) Need very light structure for 2nd stage (85kg including 52kg engine) Total system mass at launch: 6153.207 kg
Stage 3 G-Forces reduced by throttling G-Force at Stage Burnout 1 7.770246 2 15.43892 3 28.2388 Adding more liquid fuel reduces max g-forces Increasing payload mass reduces max g-forces Stage 1 burnout g-force closer to 5.5g
SpaceX tanks: 3385kg of propellant Empty stage 2: 360kg Our estimated stage 2 mass: 28.20679 kg Not including engine
Propellant mass fraction of 3nd stage 0.794451 (not ideal because motor slightly oversized, pressure fed tanks heavy) (SpaceX gets 0.91 with same engine on Falcon 1)
Biggest problem for second stage is lack of small liquid motors of high Isp in production) Upcoming LOX-Methane motors hold biggest potential by boosing Isp to 350 Given current limitations, desired change would be to get increased payload requirements, to allow bigger 1st stage) We get lower launch mass with solid upper stage, but need liquid for ISS maneuver due to restart requirements.
Oxidizer to fuel ratio for 2nd stage: Mass of liquid oxygen: Mass of Kerosene: 217.4627 kg 92.53731 kg
2.35
Tank pressure: 1.17 Mpa Total Tank Mass: 4.875 kg Helium 1 kg composite LOX 2.718284 kg alloy/composite Kerosene 1.156716 kg composite Remaining 3rd stage mass budget 23.33179 kg
Must study anti-slosh baffles for LOX tank, as SpaceX had issue with propellant sloshing with 2nd Falcon I launch.
Assumes 1 spherical tank Tank Radius Helium m LOX 0.357109 m Kerosene 0.30151 m
0.93 1.25 1.24 1.24 0.76 1.6 1.6 1.4 1.91 2,174,539 1.5 1.33 1.9 1.02 1.14 1.55 1.3 1.02 1.35 1.28
0.868
0.904
For system simplicity/reliability, pressure-fed liquid motor deemed desirable. Results of liquid motor trade study led to:
SpaceX Kestrel 2 upper stage rocket motor Currently used as upper stage for SpaceX Falcon I booster Pressure-fed LOX-RP1 rocket motor 52kg motor and nozzle Isp of 330s Flight-proven design Currently in serial production
Out of production
Upper Stage solid motors (2nd Stage) Star 17 solid USA M-V-4 solid Japan Star 37FM solid USA Star 30E solid USA Star 30BP solid USA Orion 38 solid USA Orion 50 solid USA Star 37 solid USA Star 37XFPsolid USA 1st stage solid motors ATK Orion 50XL Fiat-Avio Zefiro 9 Nissan M-3B-J MIHT-3 ATK Star 48B Nissan M-129A ATK Star 31 TX-354-3 Nissan M34 Nissan M33-20-4 ATK Castor 1 X-259 Aerotek M56A-1
USA Italy Japan Russia USA Japan USA USA/Japan Japan USA USA USA USA
170kN 300kN 132kN 245.2kN 66.0kN 77.5kN 80kN 258.9kN 294.2kN 268.6kN 237.2kN 74.0kN 228.5kN
260 260 260 255 255 260 262 262 264 247 260 250 260
416 1000 300 1000 126 360 98 695 1000 535 664 300 466
3923 10100 3300 5000 2011 1840 1286 3729 11000 3317 3692 1100 4704
0.904125 0.90991 0.916667 0.833333 0.941039 0.836364 0.929191 0.842902 0.916667 0.861111 0.847567 0.785714 0.909865
Diameter: 1.28m, 3.11m long, 69.8s burn, +- 5 degree vector control, 33.86 exp In development--not yet in production Diameter: 1.245m, TE-M-711, 84s burn
Diameter: 0.762m, TE-M-762, Antares III, 2.9m long, including nozzle, 46s burn,
Out of production
Booster Design
3 stage Booster
1st stage: ATK Orion 50XL (Solid) 2nd stage: ATK Star 31 (Solid) 3rd stage: SpaceX Kestrel 2 (LOX-RP1 liquid)
Booster Design
3rd Stage SpaceX Kestrel 2 Fairing 2nd Stage ATK Star31 1st Stage ATK Orion50XL
Interstages
Stage Specifications
Stage 1 Rocket Motor Propellant ATK Orion 50XL Solid Stage 2 ATK Star 31 Solid Stage 3 SpaceX Kestrel 2 LOX-RP1 Liquid
Empty Mass
Propellant Mass Specific Impulse Thrust Burn Time
416kg
3923kg 260s 170kN 69.8s
98kg
1286kg 293s 80kN 46s
84kg
350kg 330s 33.3kN 34s
Comparison to Pegasus
AirLaunch 1 stage maneuver Takeoff Mass Zero-velocity gravity 6,298kg PegasusXL Winged pull-up 23,130kg
Carrier Aircraft
Aircraft Mounting Payload to LEO
C-17
Internal Cargo Bay 150kg (1)
Lockheed L-1011
External Wing Pylon 443kg
Diameter
Length Upper Stage
1.7m
12.5m Pressure-fed liquid
1.27m
17.6m Solid+HAPS System (2)
(1) Payload for AirLaunch mission is 120kg fuel and 30kg satellite (2) Monopropellant hydrazine thruster for upper stage trajectory error correction
Comparison to Pegasus
Pegasus
AirLaunch
Used Joe Muellers Matlab code to simulate gravity turn Parameters that can be varied in code:
Flight Path Angle (FPA) Height at which ignition 3 starts Mass of Stage 3 Propellant
Trials 1 2 3
Targeted ISS Orbital elements
Launch trajectory:
Simulations produced the following direct launch trajectory to reach ISS:
Targeted ISS perigee altitude of 334 km
3D Orbit of Payload:
Matlab simulation produced the following orbit:
Payloads Low Earth Orbit Inclination: 51
STK simulation:
Used STK to simulate orbit of payload relative to ISS Apoapsis and Periapsis visible Enjoy the excellent video