Morpheus  Tether   Test  Readiness  Review  (TRR)  

Morpheus  Integrated  T&V  –  Jeremy  Hart  /  EG   4/20/11  

Agenda  
•  Test  Objec/ves   •  Test  Plan  
–  Overview   –  Con  Ops  

•  •  •  •  •  •  •  • 

Test  Matrix/Cases   Test  Ar/cle  Descrip/on/Configura/on     Pre-­‐Test  Verifica/on  Criteria  Review   Open  work   Test  Safety   Test  Stop  and  Success  Criteria   Test  Schedule   Backup  

2  

Test  ObjecFves  
•  Primary  Objec/ves,  Integrated  dynamic  test  of  full  vehicle:  
1.  Closed-loop GNC with 3-axis attitude control (hover stability, vertical translation)!
a)  b)  c)  d)  e)  f)  g)  Test of tank loading CG management and/or knowledge handoff to GNC! Test of throttle up stability ! Test of hover stability! Test of navigation system in dynamic flight! Test of complete flight activation and shutdown sequence by AFM! Demonstration of robustness to wind and ground prop interaction! Roll control – including roll control impulse bit!

2.  3.  4.  5. 

Characterize slosh damping! Characterize CG management! Long duration engine burn (TT Day 2) and steady state engine temp! Wireless FTS end-to-end (TT Day 2+)!

3  

Test  ObjecFves  
•  Secondary Objectives:!
1.  GNC – !
a)  b)  Possible test of soft abort command during hover flight condition! Possible test of hard abort command during hover flight condition!

2.  Calibration of flight control propellant depletion estimator (TT day 2)  

4  

Test  Plan  -­‐  Overview  
•  Pad  Setup:  Crane,  energy  absorber,  vehicle,  and  GSE   •  LOX/LNG  Fill   •  Vehicle  Hoist  –  5’  
–  Open  roll  valves  for  li[  

•  Pad  Clear   •  Pressurize  to  flight  pressure   •  Perform  tether  tes/ng  (2X)  
–  –  –  –  –  Igni/on   Handover  to  GNC   Ver/cal  transla/on  (5’  up  to  +  3’)   Hover  (30  seconds)   “Land”  at  the  end  of  tether  

•  Depressurize   •  Lower  and  weight  the  vehicle   •  Vent/Drain  tanks  
5  

 

Test  Plan:   IniFal  Crane  Setup  for  LOX/LNG  load  
•  Posi/on  crane,  vehicle,  energy  absorber   and  GSE  at  Tether  test  pad   •  Fill  vehicle  with  Lox  and  LCH4,   pressurize  to  <  50  psig  and  connect  GHe   QD   •  Leak  Check  
Energy Absorber

Crane Shield

6  

Tether  Test  –  IniFal  Set-­‐up  
New Items: -  100 ton crane -  Energy Absorber -  REMOVED straps
Bldg 18 Control Center

Energy Absorber

32 feet
APU Power Cable Battery Cart

Helium tube trailer

Pressure Panel

Lox Dewars and Trailer

LNG Trailer

GHe Disconnect
Portable GHe R-bottle

Solenoid 12V Power Supply

Portable GHe R-bottle

15 feet

15 feet 1000 feet 100 feet

Power Supply Wiring and GHe QD Lanyard

7  

Test  Plan:   Pad  Clear  and  GHe  PressurizaFon  
•  Raise  vehicle  5’  via  crane  
–  Open  roll  valves  during  li[  

•  Install  crane  shield  over  crane  cab   •  Evacuate  Cryo  dewars  and  bagery  cart   •  Transfer  to  full  GHe  tube  and  set  supply   regulator  to  300  psig   •  Clear  pad  crew  and  riggers  to  >=  1000  [   •  Pressurize  vehicle  to  flight  pressure    (~220   psig  target)  
Crane cab Shield

5’ GHe QD

8  

Test  Plan:   Engine  IgniFon  
•  Ini/ate  Quick  Disconnect  of  GHE  line     •  Engine  Igni/on   •  Handover  to  GNC  control  

3’

20’

5’ Ghe QD

9  

Test  Plan:   VerFcal  TranslaFon  
•  Ver/cal  transla/on,  5’  with  up  to  +3’   dispersion   •  Hover  (20  seconds)   •  Terminal  Descent  
–  1  m/s  descent  rate   –  “Land”  at  the  end  of  tether  

~5’

5’

10  

Test  Plan:   Depressurize  Vehicle  
•  “Land”  at  the  end  of  the  tether   •  Some  amount  of  energy  absorber  stroke   distance  (x)   •  Vent  vehicle  to  <  50  psig  
x

5’ - x

11  

Test  Plan:   Vehicle  Lowering,  Drain,  and  Flight  Secure  
•  Lower  vehicle  to  the  pad  (onto  vehicle   scales?)   •  Vent/drain  remaining  LNG/LOX   •  Flight  secure  call  when  tanks  are  drained   and  <  5  psig  

Vent line
12  

First  Day  Test  Matrix  –  IgniFon  TesFng  
Sequence    #  of   Config/Test   Success   Control  Method   #     runs     Variables   Criteria   #0   1   Thrust/weight  less   Successful   Nominal  startup   GNC   than  1   handover  to   sequence.  So[  abort  to   handoff   GNC   terminate  (before  10   seconds)   #1     1   Tether  Guidance  I-­‐ Successful   Nominal  startup   Nominal   loads   startup,   sequence.  25  second   Tether   hover,  ver/cal   hover  dura/on  a[er   Test   transla/on,   ver/cal  transla/on.   shutdown   GN&C  ConfiguraFon   •C   losed  Loop  GNC   Notes   Tank   Pressure     220  +/-­‐  5   psig      

• Closed  Loop  GNC   • Tether  Guid  I-­‐loads  

Vehicle  will   220  +/-­‐  5   remain  on   psig     tether   between  tests  

13  

First  Day  Test  Matrix  –  IgniFon  TesFng  
Sequence    #  of   Config/Test   Success   #     runs     Variables   Criteria   #0   1   Thrust/weight  less   Successful   GNC   than  1   handover  to   handoff   GNC   #1     1   Tether  Guidance  I-­‐ Successful   Nominal   loads   startup,   Tether   hover,  ver/cal   Test   transla/on,   shutdown   #2     1   Tether  Guidance  I-­‐ Successful   So[   loads   startup,   Abort   hover,  ver/cal   Test   transla/on,   so[  abort   Tank   Pressure     Nominal  startup   220  +/-­‐  5   •C   losed  Loop  GNC   sequence.  So[  abort  to   psig     terminate     Nominal  startup   Vehicle  will   220  +/-­‐  5   • Closed  Loop  GNC   sequence.  20  second   • Tether  Guid  I-­‐loads   remain  on   psig     hover  dura/on  a[er   tether   ver/cal  transla/on.   between  tests   Nominal  startup   • Closed  Loop  GNC   sequence.  20  second   •T   ether  Guid  I-­‐loads   hover  dura/on  a[er   ver/cal  transla/on.  So[   abort  at  ~15  seconds  of   hover.   So[  abort,   220  +/-­‐  5   then  hard   psig     abort  to   terminate   thrust   Control  Method   GN&C  ConfiguraFon   Notes  

14  

Morpheus Configuration for Tether Fire Test – with NEW items
LOX Tanks (X2) Tank Support Struts (X8) New DFI Box Methane Tanks (X2) Lifting Points (X4)

New Items: - FTS radios and batteries -  Latest FSW -  Tether GNC i-loads -  APU box h-bridge fix?

Primary Structure Landing Gear Accelerometers (X3)

Landing Gear (X4)

All OI and DFI in place

Landing Gear Crushable Pads (X4)

Rafael  Jiménez,  (281)  244-­‐6681  

NASA/JSC-­‐EP4-­‐Propulsion  

03/23/11  

15   15  

Morpheus  Vehicle  DFI  
Items in blue required for LN2 Inert Testing Items in blue and orange required for hot-fire and tethered test Items in blue, orange, and green required for free flight FT1 and FT3 (1 LOX & 1 LCH4 tank) Strain gauges – 100 Hz (4 sets of full bridges each tank) On all four tanks 7 TC’s on each tank – 2.1 Hz Top deck near avionics HF triaxial accel (3 HF channels) – 20 kHz LF triaxial accel (3 LF channels) – 1000 Hz Microphone (1 HF channel) – 20 kHz Pressure transducer (1 LF channel) – 1000 Hz Thermocouple (1 TC channel) – 2.1 Hz

On top of each footpad 4 LF triaxial accels (12 LF channels) – 1000 Hz

On frame at top and bottom of each tank 8 LF triaxial accels (24 LF channels) – 1000 Hz

Channel Count 5 HF channels 45 LF channels 30 TC channels 8 strain gauge full bridges

On frame Microphone (1 HF channel) – 20 kHz Pressure transducer (1 LF channel) – 1000 Hz Thermocouple (1 TC channel) – 2.1 Hz On each foot pad 4 load cells (4 LF channels) – TBD Hz 16  

Same as HF day 2

Tether  Test  Open  Work  
•  Prop  
–  –  –  –  Engine  clean-­‐up   Gimbal  performance  evalua/on  (rate  seen  during  Hot  Fire?)   Vehicle  dry  mass  balance  evalua/on  (add  ballast  as  needed)   Propellant  management  plan  –  confirm  test  matrix  can  be  completed  and  sim  

•  Rigging  Plan  
–  Crane  posi/oning  and  final  dimensions  (crane  load  set  to  20,000  lb),  pendulum   mo/on  does  not  allow  contact  with  crane  cab  (Bailey)   –  Load  tes/ng  of  straps   –  Protec/ng  vehicle  top  deck  from  slack  tether  (PVC/bungee)  –  test  in  b220   –  Mark  the  energy  absorber  so  any  stroke  caused  by  first  run  can  be  seen  at  the  RC   shack   –  Concurrence  from  crane  safety  (Steve  Daniel)  

•  EPS  
–  APU  box  fix  (ribbon  cable  re-­‐wiring,  no  FSW  change  required)  -­‐  tes/ng   –  Al/meter  source  voltage  change  to  28  V  –  need  to  test  change    

•  FTS  hard–wire  
–  Wire  fix  and  lengthened  for  tether  configura/on   –  Rou/ng  plan  for  tether  test  

17  

Tether  Test  Open  Work  –  FSW  and  GNC  
•  Guidance  Changes  
–  Guidance  fix  for  20  second  /meout  (Hot  Fire  Day  2  issue)   –  Guidance  fix  for  no  reboot  upon  double-­‐ac/va/on  

•  EMA  calibra/on  
–  Throgle/Thrust  data  calibra/on  curves   –  EMA  measurements  and  calibra/on  curves  

•  So[  and  Hard  Abort  Boundaries  under  crane  (Values:  ?)   •  Tes/ng  of  tether  runs  in  simula/on  –  with  day-­‐of-­‐test  procedures   •  Op/onal  Changes:  
–  –  –  –  –  Prop  new  temperatures  look-­‐up  table   New  hard  abort  behavior  for  EMA  control  (yes)   Nav  move  to  table  i-­‐loads  &  command  to  change  i-­‐loads  (NO  innov  day)   Make  decision  on  limit  checker  (NO  innov  day)   Prop  new  loading  sequence…methane  first  (NO  innov  day)  

18  

Tether  Test  VerificaFons  
•  Slosh  damping.  Verifica/on  that  Morpheus  provides  a  tank  slosh  damping  ra/o   of  >  0.25  over  the  full  range  of  liquid  levels.     •  Overpressure  evalua/on  –  is  5  feet  low  enough?    Li[-­‐off  from  ground?   •  Reach  steady-­‐state  on  engine  temp  (TBD  dura/on  –  is  20  seconds  ok?)   •  FSW  Tether  Dynamic  Test.    Verify  requirements  related  to  engine  trust  and   gimbal  actua/on  for  GNC  avtude  and  posi/on  control.  
•  R.RR2.FSW.062;  R.RR2.FSW.063;  R.RR2.GNC.05;  R.RR2.FSW.149  

•  Mo/on  Imagery.    Verifica/on  that  the  imagery  system  captures  hi-­‐def  mo/on   imagery  star/ng  with  igni/on  sequence  and  ending  with  vehicle  touchdown   •  Items  that  were  in  original  verifica/on  planning:    
–  Trajectory  Updates.    Verifica/on  that  Morpheus  will  accept  updates  to  the   guidance  reference  trajectory  during  powered  flight   –  Vehicle  Turnaround:  Verifica/on  that  the  Morpheus  vehicle  is  capable  of  re-­‐flight   within  2  hours  

19  

Test  Safety  
Phase   Leak  Check   Commodity   GHe  or  GN2   Pressure   Less  than  50  PSIG   Personnel   Distance   32’  for  10  min   0’  a[er  10min   15’   0’  a[er  flow  stop     32’  for  10  min   0’  a[er  10min   15’   0’  a[er  flow  stop     32’  for  10  min   0’  a[er  10  min     1000’   1000’  to  0’     RaFonal   Over  Pressure   Safe  @32’   Improbable  Rupture   Safe  @  15’   Improbable  Rupture     Safe  @  32’   Improbable  Rupture   Safe  @  15’   Improbable  Rupture     Safe  @  32’   Improbable  Rupture     Safe  @  1000’   Improbable  Rupture   RaFonal   FragmentaFon   Duc/le   Non  Credible   Duc/le   Non  Credible     Duc/le   Non  Credible     Duc/le   Non  Credible     Duc/le   Non  Credible     Safe  @  1000’   Non  Credible    

Cold  Flow  

LN2  Loading       LN2  w/  GHe     LOX  and  LCH4  Loading       GHe  Press  Leak  Check       Ghe  Flight  Press   Post  Test  

0  to  25  PSIG   Less  than  25  PSIG     25  to  50  PSIG  

Hot  Fire  

Fill  at  25  PSIG  Tank   Less  than  25  PSIG     Press  to  45  PSIG       Press  to  235  PSIG   Depress  to  50  PSIG  

Note • Improbable Rupture due to quiescent linear strain in the membrane • Non Credible due to unlikely rupture and unlikely shrapnel.

Morpheus  Required  PPE  Matrix  
Operation Crane/forklift lifting ops Vehicle prep (pre-cryo loading) PPE Hard hat, steel toe shoes, safety glasses Safety glasses, work gloves (recommended) Notes PPE needed when working inside lifting zone All vehicles parked behind helium trailer (150 foot minimum distance) to allow room for lift/tow ops. Establish 15 foot safe distance prior to flow Observe 32 foot minimum distance during pressurization and 10 minute hold PPE needed during hose connection and opening of dump valve, or if within 15 feet of dump valve All non-essential personnel observe minimum 15 foot distance from dump valve Non-essential personnel not permitted in area until tank pressure stabilizes below 25 psig and must observe all cryo offloading safe distances
21  

Cryo transfer hose hookup & valve operation

Goggles, face shield, cryo apron and gauntlet gloves, cuffless trousers, sturdy shoes Post-cryo fill vehicle ops, Safety glasses, hearing tank pressure <50 psig protection (for manual venting), cryo gloves (when contacting wetted surfaces) Cryo offloading/dumping Goggles, face shield, cryo tank pressure <50 psig apron and gauntlet gloves, (PAD personnel) cuffless trousers, sturdy shoes, hearing protection Cryo offloading/dumping, Hearing protection if within tank pressure <50 psig 150 feet (non essential personnel) Post-powered ops, tank Safety glasses, hearing pressure <50 psig protection (for manual venting), cryo gloves (when contacting wetted surfaces or hot surfaces)

*All Morpheus personnel are expected to intervene any time they observe team members or visitors not in compliance with these requirements. Help keep your team members and the public safe!

Test  Stop  Criteria  
•  Stop  Criteria  
Any  unexpected  vehicle  mo/on  –  par/cularly  laterally  towards  crane   Observed  engine  erosion  (yellow  flash)   Engine  redline  limits  –  Rob  monitoring  and  will  make  call   Loss  of  certain  instrumenta/on  sensors  –  engine  will  not  light  for  certain  sensor   failures   –  Loss  of  engine  video  feed   –  –  –  – 

22  

Success  Criteria  
•  Success  Criteria  
–  –  –  –  –  –  –  –  Stable  engine  igni/on   Handover  to  GNC  FSW   Stable  ver/cal  transla/on   Stable  hover  –  with  acceptable  gimbal  posi/on   Acceptable  engine  wear   Steady-­‐State  engine  temperature  reached   Acceptable  slosh  damping  (damping  ra/o  of  >  0.25)   Subsystem  lead  concurrence  
•  All  subsystem  leads  are  sa/sfied  that  their  subsystem  is  ready  for  tethered  tes/ng   •  FTS  has  been  verified  end-­‐to-­‐end  during  an  engine  firing   •  All  hot  fire  mandatory  verifica/ons  have  been  completed  

23  

Hot  Fire  Day  2  Test  Discrepancies    
NOTE:  This  list  does  not  include  any  discrepancies  from  data  analysis  and  review.   •  Pre-­‐test  
–  Damage  to  TTS/Vent  valve  wire  that  had  to  be  repaired.  Was  fixed  and  tested  before  tes/ng   start.    

• 

During  Test  
–  Fire  at  pad  during  script  #3,  suspected  to  have  occurred  during  the  gimbal  sweep  when  the   engine  was  firing.  May  have  been  a  sandbag.  The  fire  went  out  on  its  own.     –  TTS  cable  was  damaged  during  engine  firing,  probably  during  ini/al  run.     –  Script  #4  did  not  execute  as  plan  during  the  handover  from  GN&C  to  propulsion.  A[er   engine  igni/on,  GN&C  commanded  an  engine  shut-­‐down.  Did  not  execute  closed-­‐loop   GN&C.  The  issues  have  been  fixed  in  so[ware.   –  During  Script  #5,  the  first  igni/on  agempt  at  run  did  not  work.  Suspect  propellants  had   warmed  up.  Second  igni/on  agempt  worked.     –  During  Script  #5,  TTS  ac/va/on  caused  soo/ng  in  the  engine  but  wasn't  unexpected.  No   heat-­‐related  damage.  Will  clean  it  out  before  next  firing.  

• 

Post-­‐Test  
–  One  of  the  valve  driver  board  channels  was  completely  burned  out  during  post-­‐test   powered  opera/ons  to  troubleshoot  GN&C/FSW.  Suspected  to  be  due  to  poor  soldering  of   one  of  the  FETs.  
24  

Test  Schedule  
•  Tether  #1  scheduled  for  4/25/2011   •  Tether  #2  scheduled  for  4/27/2011  
–  Addi/onal  items  for  test:  Wireless  FTS,  Lateral  transla/on  

25  

BACKUP  

26  

Safety  -­‐  VFC  Range  DefiniFon  –  1000’  Buffer  

1000’

1500’

Tower Tether

Landing

1000’
Launch

b18

VFC Range Boundary

b14 1000’

Saturn Lane

*Scale, 1.29” = 640’

**Center,4.56, 4.22”

27  

VFC  Launch  Pad  Distances  to  Landmarks  

1500’ 2160’ 1000’
Tower Tether Launch Landing

2000’ b18 b14

2080’ 1400’

2040’

Saturn Lane

*Scale, 1.29” = 640’

**Center,4.56, 4.22”

28  

Tether  Test     VerificaFon  Entrance  Criteria  
•  FTS  –  verify  end-­‐to-­‐end  performance  (s/ll  open)   •  Prop  
–  CG  management.    Verifica/on  that  the  Morpheus  shall  maintain  a  CG  range  per   requirement  throughout  all  opera/ons.  (balance  tes/ng)   –  Gimbal  envelope  (Hot-­‐fire  day  2)  
•  Verifica/on  that  Morpheus  meets  performance  requirements  while  opera/ng  within   the  engine  gimbal  envelope.   •  Verifica/on  that  the  main  engine  is  capable  of  a  5  degree  per  second  angular  rate   •  Verifica/on  that  the  gimbal  point  is  below  the  vehicle  center  of  mass  

•  Structures  (series  of  test  at  and  above  flight  loads)  
–  Energy  Absorber.  Verifica/on  that  the  ground  system  shall  provide  an  energy   absorber  to  agenuate  tethered  loads  at  JSC  

29  

Tether  Test     VerificaFon  Entrance  Criteria  (cont’d)  
•  GNC    
–  EMA  performance  characteriza/on.    Calibrate  encoders  on  TVC  and  throgle   actuators  Run  bandwidth  response  tes/ng  on  TVC  and  throgle  actuators   Validate/update  simula/on  EMA  models  Validate  flight  performance  with  margin   in  simula/on   –  GNC  func/onal  tes/ng,  Nominal  and  off-­‐nominal  performance  evalua/on   –  Status?  

•  FSW  
–  HAST  Dynamic  simula/on.    Verify  FSW  requirements  associated  with  flight   corridor  condi/ons  and  GNC  avtude  performance  boundaries.   –  HAST  Off-­‐nominal  dynamic  simula/on.    Verify  FSW  requirements  associated  with   abort  condi/ons.   –  Status?  

30  

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