Kindly Note: This is a Daily Kos Series on a technical paper that I recently completed. To see a list of the other entries in this series, please click the link below. Thanks!
TABLE OF CONTENTS
=<<>>=
PART I | PART II
PHASE I FLIGHT TESTING
It has now been three years since the "First Shovel" ceremony, and the desert has bloomed into an oasis. Now the flying begins.
Flight testing all of the vehicles will take about one year. The RV will take up half of that time, with the rest of the vehicles taking the other six months to complete testing.
The testing order will be as follows:
- RV
- VentureStar Escape Module
- UV
- Docking with other UVs
- Docking with RV
- Inchworm Remote Manipulator System
- Spacesuit
- UV Airlock
- CM
- Docking with UV
- Docking with RV
- Spacesuit Attachment Unit
- OV
- Orbital Test
- High Orbital Test
- PM
- UV Refill
- OV Refill
- LV
- Landing Kit Attachment
- LV Refill
- Orbital Flight Test
- CV
- CV Core and Saddlebag Attachment
- CV Refill
- Orbital Test
- High Orbital Test
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RV FLIGHT TEST
The act of rolling out the very first copy of the VentureStar spaceliner should cause quite a stir. It will emerge from the RV manufacturing plant being pulled by a towbar–less aircraft tug to a cheering crowd, with Very Important People making speeches.
The first two RVs will be designated TA–1 and TA–2 (Test Articles 1 and 2). All flight testing will be conducted with these two spacecraft over a six–month period.
The test schedule is as follows:
- RV Ferry
- Ground Test
- Taxi Test
- Flight Test
- Cross Country Test
- Uncrewed RV Orbital
- Crewed RV Orbital
The RV Ferry tests should take about 3 months to complete. The orbital test should take another three months to complete.
RV FERRY
During this phase of flight testing, we will hire seasoned test pilots. They will train on the Portable VentureStar Cockpit Simulator that will be installed in the C–5A aircraft. The simulator will have the look and feel of any ordinary airline cockpit (Image 1).
We will also load a VentureStar Escape Module (VEM) into the Cargo Bay to simulate the actual weight of the spacecraft coming home from a Bingo.
The VEM will be installed into the VentureStar the same way will will load all of our cargo, which was similar to the way the Skylon was going to load its cargo. The cargo will be captured by a "grappler" that will lift it out of the cargo processing section and run it horizontally to the spacecraft and lower it into the cargo bay (see 10 second video clip below).
The RV will then have its two jet engines and external fuel tank bolted on (Image 2) [Larger Image].
The engines will be turned on and throttled up to demonstrate the design, satisfying the Ground Test part of the assessment.
The Taxi Test is next where the RV remains on the ground whilst the nosewheel steering and brakes are evaluated.
Once everything looks nominal, the first flight of our space shuttle will occur during the Flight Test. The pilots will make sure that the RV is stable and that the flight controls work.
The Cross Country flight will be the final and true test of the vehicle. The C–5A will fly in ferry mode for the first time, flying in formation with the RV. They will venture to a city, land, refuel, spend the night, then fly back.
After the RV Ferry tests have been completed, we (finally) get to fly into space!
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UNCREWED RV ORBITAL
During this phase of flight testing, we will hire seasoned astronaut test pilots, more than likely from NASA. The first flights of the RV will have to be uncrewed and controlled remotely by the test pilots like a drone.
The jet engines and external tank will be removed for these tests, with the VEM still installed. The VEM will provide a plethora of data about the upcoming spaceflight.
A towbar–less aircraft tug will tow the spacecraft out of the RV Hanger to a rail system that has a platform large enough to accommodate both the RV and tug. It will then travel along the rail using electric engines to the launch pads.
Once at the launch pad, a "grappler" will secure the spacecraft at the bottom, lift it slightly off the ground, where the landing gear will then be stowed. The "grappler will then rotate the spacecraft to a vertical position, similar to the way the X-33 would have been rotated into position ((see 17 second video clip below)).
Once the spacecraft has been rotated and secured, the propellant will be loaded, and the spacecraft is ready for launch (Timeline in table below).
|
START |
END |
DURATATION |
Preflight Preparation |
0:00 |
|
|
Payload Installation |
0:00 |
0:30 |
0:30 |
Close Payload Doors |
0:30 |
0:35 |
0:05 |
Flight Ready Checks |
0:35 |
0:40 |
0:05 |
Hanger Flight Checks |
0:40 |
0:50 |
0:10 |
Deliver to Launchpad |
0:50 |
1:15 |
0:21 |
Install on Launchpad |
1:15 |
1:21 |
0:10 |
Rotate to Vertical |
1:21 |
1:31 |
0:10 |
Nitrogen Purge |
1:31 |
1:41 |
0:10 |
Tank Chill Down |
1:41 |
1:51 |
0:10 |
Propellant Loading |
1:51 |
2:36 |
0:45 |
Flight Ready Hold |
2:36 |
2:37 |
0:01 |
Final Flight Checks |
2:37 |
2:38 |
0:01 |
Liftoff |
2:38 |
|
|
After clearing the launch pad, the RV will rotate to "heads–down" configuration as it turns to intercept a 60–degree inclination and 900 km altitude. The rocket engines will be tested for the first time during this flight. We will be particularly interested in the performance of the RV from Max–Q to MECO.
Once in orbit, The spacecraft will be put through its paces, testing various equipment and hardware. The RCS will be used to reorient the RV.
After about 24 hours in orbit, the VentureStar will deorbit for an entry into the Earth's atmosphere and a Return To Base (RTB). We will test the Thermal Protection System (TPS) and aeronautical flight controls during this time.
The RV will then perform an unpowered glide landing back at Spaceport America.
The vehicle will be scrutinized for any anomalies that may have occurred during the spaceflight. The RV will then spend 5 days in the hanger being refurbished for reuse (Timeline in table below).
|
START |
END |
DURATION |
Full Stop |
0:00 |
|
|
Runway Safety Checks |
0:00 |
0:10 |
0:10 |
Tow Truck Attachment |
0:10 |
0:12 |
0:02 |
Tow to Hanger |
0:12 |
0:32 |
0:20 |
Install in Hanger |
0:32 |
0:42 |
0:10 |
Hanger Post Flight |
0:42 |
0:52 |
0:10 |
Open Payload Doors |
0:52 |
0:57 |
0:05 |
Remove Payload |
0:57 |
1:27 |
0:30 |
Prepare for Refurbishment |
1:27 |
|
|
The second spaceflight of the RV will be a duplicate of the first, except this flight will last nine days, testing its endurance.
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CREWED RV ORBITAL
The first crewed flight into space will be a major milestone as well as a monumental historical event.
A crew of ten test pilot astronauts will enter the VEM and strap into their seats. After the hatch closes, the same abbreviated checklist will be used as if it were ordinary cargo. They will go on a one–day mission into space.
Once in orbit, the crew confirms the integrity of the spacecraft and the VEM.
The RV orientation will also be tested. We believe that the most exciting for the crew would be for the spacecraft to maintain a tail–down / nose–up orientation, keeping the Earth "below" and "space" above. The VEM windows become vertical, providing superior views of the planet below. Passengers also need to have a sense of up and down to aid in space adaptation syndrome.
After a (hopefully) uneventful mission, they RTB and land in the middle of history.
The last orbital crewed flight test of the VentureStar will be a duplicate of the first mission, except this mission will last nine days. The astronauts will demonstrate the durability of the spacecraft.
After a successful last flight test mission and RTB, the VentureStar may be classified as operational.
By this time, the next RV will have been towed out of the manufacturing plant. It will be designated 01A, which means the first spacecraft of the first 17 total spacecraft. The "Alpha" series will be followed by the next set of 17 which will be called the "Bravo" series, followed by the "Charlie" series, and so forth. Each series will be completed every four years.
Our design should endure for the next forty years, which means we should be able to manufacture the RVs all the way up to the "Juliet" series.
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UV TEST
Next up is the Utility Vehicle (UV) or space tug (Image 3) [Larger Image].
There are three systems that need to be tested:
- Reaction Control System
- Airlock
- Docking
Since each fully loaded UV has a mass of 5,217 kg, four UVs can be loaded into an RV:
Mass To Orbit = 4(UV Mass)
= 4(5217)
= 20,868 kg
RCS TEST
All four UVs will deploy and use their RCS to test their maneuverability. We will monitor propellant use rate, leaks, temperatures, mechanical issues, etc.
AIRLOCK TEST
During the RCS tests, the airlocks will cycle to test their ability to hold and release one atmosphere of air pressure. We will monitor the airlock for leaks, mechanical issues, etc.
DOCKING TEST
Two of the UVs will have their airlocks rotated 45 degrees so that two UVs can dock together without interfering with each other's RCS (Image 4) [Larger Image].
Once all of these tests are complete, the UV may be classified as operational.
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CREW MODULE TEST
The Crew Module (CM) is the next item up for testing. The CM will never be operated alone; it will always be attached to a vehicle that a crew will control remotely.
We will therefore attach two UVs to our test CM, one at the top of the vehicle and one at the bottom (Image 5) [Larger Image]. They will be installed into the cargo bay of the VentureStar in this configuration. Our Crew Module will be a tCM1_04–04–46–4049, meaning that it is a one–level ship with four astronauts and four spacesuits on a forty–six day mission with a mass of 4,049 kg.
Once lifted into orbit, it will become the first cargo flight for our organization (Table below). It will be taken out of the cargo bay by two inchworm RMSs. The inchworms will remain with the test CM.
Utility Vehicle |
5,217 |
kg |
Crew Module |
4,409 |
kg |
Utility Vehicle |
5,217 |
kg |
Remote Manipulator System |
65 |
kg |
Remote Manipulator System |
65 |
kg |
Total Payload Mass |
14,613 |
kg |
Once the test CM is outside of the RV and secure, the VentureStar will RTB, leaving the CM in orbit. The CM will be remotely controlled from Mission Control at Spaceport America.
Another VentureStar, loaded with a VEM and a crew of 10, will liftoff to rendezvous and dock with the test CM. Four spacesuits will accompany the crew into space.
Once docked, 4 test pilots and the four spacesuits will transfer to the CM. They will remain docked for two days to do a thorough systems check of the CM.
If everything looks nominal, the CM will undock with the four crew members on board, allowing them to conduct a more detailed test of the CM. The other 6 astronauts aboard the VentureStar will RTB.
The six astronauts remaining in orbit will live and work in the CM for several days. During this time they will test the food preparation system, the toilet and shower, maneuverability, etc.
If everything still looks nominal, the CM may be classified as operational, and the crew will move on to the testing of the spacesuit.
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SPACESUIT TEST
Now that our test CM is is good shape, it is now time to use the UV airlock to test the spacesuits.
The Portable Life Support System (PLSS) or "backpack" is detached from two of the suits. Two of the four astronauts ingress into their spacesuits from the back and the other astronauts help to reattach the PLSS.
After a systems check, they enter the UV airlock attached at the top of the CM. After depressurization, they open the hatch, tether themselves, and step out into more history.
The Extra Vehicular Activity (EVA) will test the suit, noting its flexibility, any leakage, pressurization variations, etc. After a few hours, they will return to the UV and re–pressurize the airlock and triumphantly reenter the CM.
After a few days of debriefing, the other two astronauts will take their turn.
Once the four spacesuits have been demonstrated to operate nominally, the next phase of testing begins.
The original two astronauts will don their space gear again, and once again go outside. This time, however, they will attempt to "click in" to the EVA ports on the side of the CM. Once attached, the crew inside will open the interior hatch and detach the PLSS, allowing the astronaut to egress (Image 6).
The other two crewmembers then EVA and "click in" to the remaining EVA ports. They will allow for a few days to ensure the integrity and safety of the ports.
The crew will now spend the remaining time in space performing several spacewalks using the EVA ports.
Once all of the tests are complete, the spacesuit and CM EVA ports may be classified as operational.