All Roads Lead to Launch Pad

A large truck can transport a rocket component the size of one engine. But how do you transport a piece as tall as, say, the Leaning Tower of Pisa to a launch pad?

SLS (Space Launch System) Pathway To Launch Pad

All roads lead to the pad is a good way to explain how the Orion spacecraft for future interplanetary space travel will occur.

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A large truck can transport a rocket component the size of one engine. But how do you transport a piece as tall as, say, the Leaning Tower of Pisa to a launch pad?

NASA is preparing for the first of many flights of the agency’s Space Launch System rocket and Orion spacecraft. Every day we’re making progress toward their first integrated test flight. Today, that work is taking place at numerous sites around the country, but the work of that nationwide team is firmly focused on one place – the launch pad.

Hundreds of companies across every state have been a part of SLS and the Orion crew spacecraft, many of them small businesses providing specialized components or services. That work comes together at NASA and prime contractor facilities where the “big pieces” are assembled before it all comes together on the launch pad at NASA’s Kennedy Space Center in Florida.

A crane lifts the ICPS test article out of a shipping container.

A test article of the Interim Cryogenic Propulsion Stage was delivered to Marshall Space Flight Center from United Launch Alliance in June.

1) Second Stage, From Alabama to Florida by Barge

Some of the pieces have a relatively direct route to the launch pad. At Marshall Space Flight Center in Huntsville, Alabama, where the SLS program is managed, for example, the flight unit for the Orion Stage Adapter (OSA) that will connect the SLS second stage to the crew spacecraft is being welded, and welding will begin next month on the Launch Vehicle Stage Adapter (LVSA) that will connect the core and second stages. When completed, the LVSA will travel by barge to the gigantic Vehicle Assembly Building (VAB) at Kennedy Space Center (KSC) in Florida, where final stacking of SLS and Orion will take place. The smaller OSA has the option of barge or truck, and after arriving in Florida, will make a stop at a facility where 13 CubeSats will be installed before continuing on to the VAB.

Half an hour away, the second stage of the rocket, the Interim Cryogenic Propulsion Stage (ICPS), is being completed at the United Launch Alliance facility in Decatur, Alabama. The process for the ICPS will be one step longer – after being barged from Decatur to Florida, the stage will be prepared for flight at a payload processing facility before being moved to the VAB for stacking.

Booster segments being delivered by train to Kennedy Space Center during the space shuttle era.
Booster segments being delivered by train to Kennedy Space Center during the space shuttle era.

2) Boosters, From Utah to Florida by Train

Propellant is already being cast into booster segments for the first flight of SLS. The boosters will be transported by train from an Orbital ATK facility in Utah to Florida. Since the 17-story-tall boosters are far too long to be transported in one piece, the boosters will be transported in segments. They’ll arrive at a processing facility at Kennedy before being moved to the VAB where they’ll be stacked vertically and joined by the rest of the rocket.

NASA’s large Pegasus barge will be able to transport the SLS core stage, which will be more than 200 feet long.

3) Engines and Core Stage, From Mississippi to Louisiana to Mississippi to Florida By Barge

This one’s a little more complicated. RS-25 core stage engines are currently in inventory at Stennis Space Center in Mississippi, where engine testing is taking place. The core stage hardware for the first launch of SLS is currently being welded at Michoud Assembly Facility in New Orleans. The engines for the first flight will be transported from Stennis to Michoud, and integrated into the first core stage when it’s completed. The core stage with engines will then be transported back to Stennis, where the 212-foot-tall stage-and-engine assembly will be placed into a test stand and all four engines will be fired together in the largest liquid-engine ground test since Apollo. After the test, plans call for the stage to be shipped to Kennedy by barge, where it will be brought to the VAB for assembly with the rest of the rocket.

The crawler-transporter is capable of transporting 18 million pounds from the VAB to the launch complex.

4) Rocket, From VAB to Launch Pad via Crawler

Once all of the elements have arrived at the VAB, they’ll be stacked vertically and prepared for launch. The large crawler transporter will bring the mobile launcher with tower to the rocket, and will then carry rocket and launcher together to the launch pad. Which leaves only one last step:

5) Orion, From Launch Pad to Deep Space, via Rocket

NASA is on track for the first mission to launch no later than November 2018 from Florida. The first test flight of SLS and Orion will be incredible, and it will pave the way for our second exploration mission – our first with crew aboard the spacecraft. As these missions continue to come together, we’re closer to sending astronauts to Red Planet than at other point in our history. All the work we’re doing together today will continue to enable that journey in the future.

Written By: DHitt NASA

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UNIVERSAL DIGEST is pleased to be a conduit for some of NASA’s projects and work. This article and some others were written by NASA and are mostly unedited. We do not claim credit, we simply want to make them more available to the general public.

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BEHIND THE SCENES NASA QM-2 TEST FIRING

Behind the Scenes of the NASA QM-2 Largest Ever Rocket Booster

For two monumental minutes on June 28, the Space Launch System (SLS) solid rocket boosters — the largest ever built for flight — will fire up in an amazing display of power as engineers verify their designs in the last full-scale test before SLS’s first flight in late 2018. Each piece of hardware that’s qualified and each major test — like this one, dubbed QM-2 — puts NASA one step closer on its Journey to Mars. Let’s take a look behind the scenes.

The smoke and fire may last only two minutes, but engineers at NASA’s Marshall Space Flight Center in Huntsville, Alabama and Orbital ATK in Promontory, Utah have been preparing weeks — even months — in advance for the static test of Qualification Motor 2 (QM-2). Here’s a behind-the-scenes look at what goes into getting ready to fire up the largest and most powerful solid rocket motor ever built for flight.

T (for test) minus weeks and months. In the months prior to the test, propellant-filled segments began arriving at Orbital ATK’s Test Bay T-97 after being cast in nearby facilities. Many of these segments are veterans of space shuttle flights. In fact, the various metal case segments that comprise the five-segment QM-2 motor flew on 48 shuttle flights!

T minus 14 days. In the two weeks leading up to the test, Orbital ATK engineers begin dry runs behind the scenes that simulate the final test as closely as possible (without the smoke and fire). They put the motor and associated systems through their paces no fewer than 11 times before the big day to ensure not only that all systems are functioning as expected, but also that the test will be executed properly. “We only get one shot at firing the rocket motor,” says Dr. Janica Cheney, Orbital ATK’s director of Test Operations. “All the dry runs and other preparations that take place ahead of time are critical to ensuring we get the data we need from this test firing.”

NASA and Orbital ATK test SLS Qualification Motor-2 (QM-2) before first flight.

Are you ready? It’s time for the final full-scale test before the first flight test of the SLS solid rocket motor June 28 at 10:05 a.m. EDT (8:05 a.m. MDT). Many cameras record data during the test, such as this one which captures nozzle plug performance during the test.

T minus 24 hours. For this final full-scale static test, engineers have 82 goals, or test objectives, they need to measure and evaluate. One day before the test, it’s crunch time; caffeine’s flowing as engineers work around the clock behind the scenes the day before the test to ensure all systems function properly and all necessary data can be collected.

T minus 8 hours. Game day. There’s focus — and excitement. There are two more dry runs leading up to the test. Engineers, technicians and operators are “on station,” — present and accounted for at key locations such as the test bay, the instrument rooms and the control bunker. When you hear “control bunker,” think mission control — a command and control center that directs every aspect of the test, similar to what you see at mission control during a launch. Time flies during the final eight hours before the test.

Orbital ATK’s Test Bay housing rolls back to reveal Qualification Motor-2 (QM-2).

At T minus 6 hours with a “go” decision for testing QM-2, engineers at Orbital ATK will roll back the booster test bay housing so the massive motor can be fired.

T minus 6 hours. At 4:05 a.m. EDT (2:05 a.m. MDT), engineers and managers at Orbital ATK and NASA will make a “go” or “no go” decision on testing that day. Assuming the test’s a go, technicians “roll back” Orbital ATK’s specially designed moveable test bay housing and begin running final checks to make sure everything is ready. “We check the status of all the data and control systems, the test bay, the motor preparation and weather conditions,” Cheney says.

Weather is one variable that can halt the QM-2 test. “We make sure there’s no lightning in the area; no high winds; no storms,” explains Orbital ATK Fire Chief Blair Westergard. “We also establish fire breaks. Along with the Box Elder County Fire District, we’re prepared to extinguish any secondary wildfires too.”

Engineers also make sure cameras are ready to film and all data recording systems are online and functioning properly. Orbital ATK Security ensures the area around the test is clear.

T minus 3 hours. Crowds begin to gather as the public viewing area near Promontory off State Route 83 opens at 7:30 a.m. EDT (5:30 a.m. MDT). Orbital ATK Security directs traffic with the help of the Utah Highway Patrol and provides crowd control support to ensure everything remains orderly — vital when 10,000 people are in attendance.

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T minus 1 hour. The formal countdown commences; the public address system broadcast begins. The crew in the test bay begins final procedures to prepare the booster for testing.

T minus 9 minutes. Final system and timing checks are underway.

T minus 4 minutes. A “go for test” announcement sounds from the public address system.

T minus 1 minute. A siren begins; it will blare through T minus 20 seconds.

T minus 45 seconds. The “Safe and Arm” system sequence begins, which arms the motor. The Safe and Arm device is remotely activated from the “safe” position into the “armed” position, allowing the motor to ignite when the “fire” command is given.

T minus zero. At 10:05 a.m. EDT (8:05 MDT), two minutes of pure awesome commence as the gigantic motor burns through about five and a half tons of propellant each second during the approximately two-minute test. Behind the scenes and inside the control bunker, there will be jubilation — and relief. “This is serious business — this is rocket science,” Cheney emphasizes. “But there’s nothing better than the smoke and fire and the data that comes with it when you’ve had a successful day. Our success is NASA’s success — we don’t do it alone.”


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Written By: Beverly Perry


UNIVERSAL DIGEST is pleased to be a conduit for some of NASA’s projects and work. This article and some others were written by NASA and are mostly unedited. We do not claim credit, we simply want to make them more available to the general public.

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Small Hitchhikers Ride Through The Galaxy

Small Hitchhikers Ride Through The Galaxy

On the first launch of the Space Launch System (SLS), America’s next-generation heavy-lift rocket, the Orion Stage Adapter (OSA) will carry some small, Space Hitchhikers in the form of 13 CubeSats, or boot box-sized science and technology investigations, that will help pave the way for future human exploration in deep space. Engineers and technicians at NASA’s Marshall Space Flight Center have built the main structure of this hardware that will be part of the rocket when it lifts off from Launch Complex 39B at NASA’s modernized spaceport at Kennedy Space Center in Florida.

 

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Jennifer Takeshita, the lead for friction stir welding at Teledyne Brown Engineering, compares a model of the Orion Stage Adapter (OSA), including brackets to secure CubeSats (space hitchhikers) during their spaceflight, to the flight hardware nearing completion at Marshall Space Flight Center.

The Orion Stage Adapter does exactly what its name indicates: it connects the Orion spacecraft to the second stage of the launch vehicle. Using enormous friction-stir welding machines, engineers just finished welding three large panels into a ring that is 18 feet in diameter and 5 feet high. With this welding complete, it’s time for analysis. The main structural ring is currently undergoing nondestructive analysis using 3-D structured light scanning and photogrammetry, which creates a computer model using photography, to ensure hardware was built to design specification.

 

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Engineers use 3-D structured light scanning and photogrammetry to analyze the main structure of the Orion Stage Adapter (OSA) at Marshall Space Flight Center. Targets for the optical scanner and SLR camera can be seen on the aluminum structure. Solid modeling software will combine the images into a single computer model so engineers can compare finished hardware to the design.

Next, engineers will trim it, weld upper and lower rings onto the large ring, machine it to final dimensions, apply paint, and install the diaphragm, a barrier that separates SLS from Orion. After that, installation of cables and the brackets that will secure the secondary payloads during their spaceflight will complete this critical piece of flight hardware.

The 13 CubeSat secondary payloads will be some of the first small satellites to explore deep space and answer critical questions relevant to NASA’s future exploration plans. These small but mighty scientific investigations include ten satellites from U.S. industry, government, and commercial partners as well as the three CubeSats being built by international partners. These small hitchhikers not only will save money, they will advance scientific research by leaps and bounds.

Written By: Beverly Perry


UNIVERSAL DIGEST is pleased to be a conduit for some of NASA’s projects and work. This article and some others were written by NASA and are mostly unedited. We do not claim credit, we simply want to make them more available to the general public.

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The Rocket Comes to the Rocket City

Over the next year, the rocket comes to the Rocket City in a big way.

Huntsville, Alabama, a.k.a. “Rocket City,” is home to NASA’s Marshall Space Flight Center, where today the Space Launch System (SLS), the powerful rocket NASA will use for human exploration of deep space, is being developed.

More than six decades ago – before NASA even existed – Huntsville laid claim to the nickname thanks to its work on missiles and rockets like the Juno that launched the first American satellite or the Redstone used for the first Mercury launches.

In the years since, Huntsville, and Marshall, have built on that legacy with work on the Saturn V rockets that sent astronauts to the moon, the space shuttle’s propulsion systems, and now with SLS.

 

Tower 4963 NASA

A steel beam is “flown” by crane into position on the 221-foot-tall (67.4 meters) twin towers of Test Stand 4693 during “topping out” ceremonies April 12 at NASA’s Marshall Space Flight Center in Huntsville, Alabama.

While the program is managed at Marshall Space Flight Center, contractors around the country are building the rocket. Engines are being tested in Mississippi. The core stage is being built in Louisiana. Booster work and testing is taking place in Utah. Aerospace industry leaders and more than 800 small businesses in 43 states around the country are providing components.

The Marshall team has also been involved with the hardware, largely through testing of small-scale models or smaller components. The center also produced the first new piece of SLS hardware to fly into space – a stage adapter that connected the Orion crew vehicle to its Delta rocket for Exploration Flight Test-1 in 2014 (See Orion’s First Flight for more.) The same adapter will connect Orion to SLS for their first flight in 2018.

 

SLS Top Half Test Version

In image above workers prepare the top half of a test version of the SLS Launch Vehicle Stage Adapter. The completed adapter will undergo structural testing at Marshall later this year.

Now, however, big things are happening in the Rocket City. The new Orion stage adapter for the upcoming launch is being built. The larger Launch Vehicle Stage Adapter, which will connect the core and second stages of the rocket, is being built at Marshall by contractor Teledyne Brown Engineering. This year, test versions of those adapters and the Interim Cryogenic Propulsion Stage (ICPS) will be assembled into a 56-foot-tall stack, which will be placed in a test stand to see how they handle the stresses of launch.

Those test articles built locally will be joined by larger ones produced at the Michoud Assembly Facility outside New Orleans. Test versions of the rocket’s engine section, oxygen tank and hydrogen tank will be shipped by barge from Michoud to Marshall. Two new test stands – one topped out last month at 221 feet tall – have been built at Marshall, joining historic test stands used to test the Saturn moon rockets.

The Payload Operations Center at Marshall Space Flight Center

In addition to rocket development, Marshall is involved in numerous other efforts, including supporting all U.S. scientific research conducted aboard the International Space Station.

Fifty-five years ago this month, Alan Shepard became the first American in space riding on a Redstone rocket, named for the Huntsville army base where his rocket had been designed – Redstone Arsenal. Today, Marshall, located on the same red clay that gave the arsenal and rocket their name, is undertaking perhaps its largest challenge yet – building a rocket to carry humans to the red stone of Mars.

Huntsville grew substantially from its small Southern town roots during its early days of rocket work in the 1950s and ‘60s, and Marshall has gone on to be involved in projects such as Skylab, Spacelab, the Hubble Space Telescope and the International Space Station, to name a few. But despite branching out its work both in space and other technology areas, Huntsville remains the Rocket City.

…After all, we built this city on a rocket role.

Written By: David Hitt


UNIVERSAL DIGEST is pleased to be a conduit for our contributing authors. We do not claim credit; we simply want to make it more available to the general public. And, the opinions of the authors are not necessarily the opinion or stance of this website, advertisers, assigns, or affiliates.

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