Major Tom: Lunar Cargo Transport

Mai Lee Chang

Miguel Gallego

Travis Marks

Pete Penegor

Miao Zhang

EMA 569

Dr. Elder

Prof. Hershkowitz

DESIGN INTENT

To design an unmanned cargo transportation system to deliver materials from Low Earth Orbit to the lunar surface in support of a lunar base.

Deliver at least 5 metric tons (mT) of cargo in 6 months or less.

PRODUCT DESIGN SPECIFICATION

MISSION OVERVIEW

WHAT IS MAJOR TOM?

Ion Propulsion System Lunar Lander

Cargo Capsule

MISSION OVERVIEW

Engine Cargo Lander

LAUNCH VEHICLE

SpaceX Falcon 9 Heavy 26.3 mT of cargo to LEO Launches to inclination

of 28.5 degrees Total cost of $94.5

million

LAUNCH VEHICLE FAIRING

First launch: The engine and lander

must fit inside of the fairing.

Subsequent launches: Cargo capsule must fit

inside of the fairing.

LOW-THRUST TRAJECTORY

LOW-THRUST TRAJECTORYTransfer Time = 158 daysDry Mass Delivered= 18 mTFuel Required = 4.402 mTDelta-V = 7.51 km/s

ION PROPULSION SYSTEM

ION PROPULSION ENGINE

VASIMR VX-250 (Variable Specific Impulse Magnetoplasma Rocket)

Power = 250 kW Trip to LLO

Isp = 3,500 s T = 12 N

Trip back to LEO Isp = 3,000 s T = 14 N

ENGINE STRUCTURE

The engine is supported by an aluminum structure 7075-T6 Members

SAE AMS 4049K SAE AMS 4154N

2117-T4 Rivets MS20470 AD 3-9

3 m

1.8 m

EXTERIOR OF ENGINE STRUCTURE

Whipple Shields

Radiators

FUEL/AVIONICS STRUCTURE

Aluminum/Titanium structure for fuel/avionic

6Al-4V Titanium bars per MIL-T-9046

7075-T6 Al platesper SAE AMS 4149K

3.2 m

2.75 m

FUEL SYSTEM AND AVIONICS

2 plates supporting 4 Argon fuel tanks each Composite Overwrap Pressure Vessels Each tank holds 655 kg

1 plate supportingavionics and RCS fueltanks LOX, Methane tanks Helium tank AutoGNC

EXTERIOR COMPONENTS

RCS Thrusters

Avionics

EXTERIOR OF FUEL/AVIONICS STRUCTURE

Stowed Solar Panels

Whipple Shields

Backside

Active Docking System

4 m

6 m

DEPLOYED SOLAR ARRAYS

Deployed solar panels SLASR Arrays Two wings 18.4 m x 10.4 m each 30 mm of glass

radiation protection PBOL = 298.5 kW PEOL = 268.7 kW Total weight = 500 kg

CARGO CAPSULE

Major Tom

CARGO CAPSULE

Propulsion and Avionics Module

Integrated Cargo Module4 m

11.4 m

CARGO CAPSULE: INTEGRATED CARGO MODULE

• 24-ply toughened graphite bismaleimide composite facesheet (IM7/5260)

• Titanium alloy honeycomb (Ti-3Al-2.5V) sandwich core

6Al-4V Titanium alloy angles per SAE ASM 9046J

Egg-Crate Structure

INTEGRATED CARGO MODULE

Passive Docking System

6 m

Electrical Connector

Guidance Cone

Fluidic Connector

INTEGRATED CARGO MODULE

96 Threaded Pin Puller Mechanism

Core Structure

Releasable Cargo Pallet

RELEASABLE CARGO PALLET

Passive Flight Releasable Grapple Fixture

RELEASABLE CARGO PALLET

5X Passive Flight Releasable Attachment Mechanism

RELEASABLE CARGO PALLET

1. 5X International Standard Payload Rack

2. 5X Active Flight Releasable Attachment System

INTEGRATED CARGO MODULE

2 Aluminum Plated Whipple Shield Al 2219-T851 (3 mm Thick) Al 5083 (1.2 mm Thick)

Multi-Layer Insulation Intermediate Stuffing Layer

2 layers Ceramic Fabric (Nextel 312-AF-10)

3 Layers Kevlar (KM2 SEAL 364)

CARGO CAPSULE: AVIONICS & PROPULSION MODULE

Avionics

Active Docking System

Liquid Methane Tanks

5.4m

4.0m

CARGO CAPSULE: PROPULSION Refuel VASIMR and Lunar Lander In-situ resource utilization (ISRU)

Oxygen: refuel two ascent vehicles per year

Methane: 2,160kg per year Propellant Tanks:

Material Unit Mass(kg) Press(Mpa) R(m) Tot.Mass(kg)

Liquid OxygenAl-Li 2090 liner & graphite epoxy composite 18 2.24 0.16 18

Liquid MethaneAl-Li 2090 liner & graphite epoxy composite 543 2.24 0.56 3,257

Helium

Inconel 718-liner, graphite epoxy composite 136 41.37 0.42 136

Gaseous ArgonTitanium liner & carbon fiber composite 904 31.03 0.47 5,424

CARGO CAPSULE: PROPULSION Mount: Al skirt Thermal Control: multi-layer insulation blankets Sensors: pressure transducers, type T

thermocouple internal probes RCS Thrusters: LOX/Meth, XCOR Fuel Transfer:

Diameter=3.0cm 302 SS pipes per SAE J615

Methane tanks mounted with Al skirt on plate

Diameter=3.18m

CARGO CAPSULE: AVIONICS Guidance, Navigation, and

Control GPS: General Dynamics Inertial Measurement Unit:

Honeywell Star Tracker: Micro ASC

Orstead DTU Communication

S-Band UHF Band

Computers Fault Tolerant Computer (FTC) FTC Electronic Boxes Monitoring and Safing Unit

Power: Solar, lithium batteries

Diameter=2.35m

Diameter=1.25m

CARGO CAPSULE: ACTIVE DOCKING SYSTEM

Retractable Probe

Fluidic connector

Electrical connector

Diameter=0.5m

CARGO CAPSULE LANDING GEAR Based on Apollo Lunar Module Launch: stowed LEO: deployed Requirements:

Structural Mechanical Landing performance

Three main components: Primary Strut:

Al 7075 per ASTM B221 Secondary Strut

Al 7075 per ASTM B221 Footpad

Aluminum Foam Deployed Position

2.07m

1.00m

Dia=0.80m

CARGO CAPSULE: MASS DISTRIBUTION

Mass (kg)

Structure 5,034

Propulsion 3,073

Avionics 96

Cargo Capacity 8,297

Total 16,500

LUNAR LANDER

LUNAR LANDER: DESCENT AND ASCENT

Low Lunar Orbit (LLO)- 100km Descent

1. Initial De-Orbit Burn2. Powered Descent3. Vertical Landing

Ascent1. Detach from cargo2. Continuous thrust3. Orbit Insertion Burn

CENTER STRUCTURE

End plates 20mm Thick Aluminum 7075-T6

as per AMS 4049K Vertical supports

Aluminum 7075-T6 Fasteners

18/8 Stainless Steel Bolts as per ASTM F593

CENTER STRUCTURE

Fuel Tanks 10mm Thick Al-Li 2090, Graphite Epoxy

Various diameters Oxygen Tanks: 530mm, 480mm Methane Tanks: 260mm, 280mm, 320mm

Notches for support 10mm spacing

Fuel Tank Spacers/Holders 10mm Thick Aluminum 7075-T6

SKIN

Skin pieces 10 mm Aluminum 7075-T6

as per AMS 4049K Fasteners

2117-T4 Aluminum Rivetsas per MS20470

Attached to vertical supports

TRUSS STRUCTURE

Truss Aluminum 7075-T6 Swing out 90 deg

Stowed area 0.3m x 0.6m x 1.0m

TRUSS DEPLOYMENT

Torsional spring SpaceDev’s

SH-18010 Hinge Actuators

SpaceDev’s EH-3525304 Stainless Steel

Swing Arms Aluminum 7075-T6

Resting plate Aluminum 7075-T6

Hinges Sealed Deep Groove

PROPULSION SYSTEM

Two CECE Engines Thrust: 80360 N Weight: 77 kg

RCS Thrusters 20 XCOR CH4/LOX Double up in middle

POWER/AVIONICS

Power Solar Panel

Stretched Lens Array Regenerative Fuel Cell

Lithion Model L1147

Avionics Similar to VASIMR/Cargo Capsule ALHAT System

Flash Lidar Altitude Velocity Terrain Relative Navigation Hazard Detection and Avoidance

QUESTIONS