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In multistage launch vehicles the spent stages separation process is broadly classified in to two classes.
Dynamics of atmospheric separation is very complex due to the presence of aerodynamic forces and
moments acting on the separating bodies. On the other hand upper stage separation is comparatively
simpler due to benign environment.
Lower stage or strapon separation as the name indicates are the rocket motors strapped on to
the core motor to boost the payload capability of the vehicle by on board command once their
intended functions are over. The direction of separation can be fixed to avoid collision hazards to the
core vehicle, unlike the separation of other stages, which are usually in the axial direction, separation
and jettisoning the strapons is one of the most challenging tasks due to the complexity of separation
dynamics analysis involved particularly when the strapons are to be separated at high dynamic
pressure environment and when more number of strapons are involved in the separation process.
1) The separation system joints must provides a rigid attachment with the core vehicle to effectively
transfer the strapon thrust and control forces to the core vehicle and must withstand the aerodynamic
loads that are expected in fight.
2) The strapons must separate on command as pr the designed flight sequence and the separated
strapons must be jettisoned with sufficient energy; to ensure no collision with the core vehicle.
During the last two decades, the demand for heavier spacecraft mass has been made to satisfy the
increased user requirements. Accordingly multistage launch vehicles are configured with large sold
strapon boosters. The separated body should not rebound and collide with the core vehicle by the
action of impingement of jettisoning jet plume. The separation disturbances shall be within the control
capability of the core vehicle. As the spent stage inert mass is very heavy about 30 tons, the selected
system should provide strong thrust and be able to withstand the tail off thrust of spent strapon stage.
Considering all these, side rocket system has been chosen as jettisoning system.
The booster stages are separated from the vehicle during it’s tail off thrust and the thrusting phase (
control is on ) of the core vehicle by the severing strapon joints (ball and socket)at the top and the
three strapon links at the aft end of the pyro assisted mechanism. The jettisoning rockets are mounted
in the nose cone and the base shroud provides the necessary separation velocity for the booster stage
to achieve separation .This is achieved by employing 5 number of side rockets per strapon (2 numbers
at the forward end 3 numbers at the aft end so that the spent body can be taken away from the vicinity
of the functional stage. The number of sides rockets 2 at the forward end and 3 at the aft end are
decided in such a way that the ;spent body will be moving with out any rotation as the spent body
C.G. is placed towards the base shroud.
The primary function of heat shield is to protect the payload and other sensitive system of launch
vehicle from the aerodynamic and thermal loads during its ascent phase of flight and to provide the
aerodynamic shape and thereby reduces the aerodynamic drag. After meeting the functional
requirements the heat shield should be separated from the launch vehicle as early as possible. The
system used for separation should impart necessary jettisoning velocity to achieve collision free
separation. The heat shield is usually made in two halves and attached through separation
system. The velocity required for safe separation depends on the heat shield diameter, mass,
flexibility and the state of motion. However as the diameter and length of the heat shield goes up
flexibility plays a major role in safe separation. Also for many vehicles the heat shield separation takes
place in thrusting phase. All these factors necessitate a larges separation velocity and jettisoning
system to impart this velocity as quickly as possible. For these reasons the PSLV and GSLV have
adopted a zip cord as jettisoning system for vertical separation. The separation dynamics of heat
shield is studies by combining the rigid body as well as flexible motions of the fairings using finite
element method.
A merman band type separation system with bolt cutters on either side is provided at the space craft
payload interface. 12 helical spring thrusters mounted in the payload adapter provides the necessary
separation velocity of 1 m/s to the spacecraft. The specifications of spring thrusters used were given
in table 1 the separated cryo stage residual gas of the storages tank container provides a large number
of thrust generation sources. These thrust sources are quantified and their thrust action points were
identified. Using table 1 and residual forces and moments generated separation dynamic analysis are
carried out for short term and long term collision hazards. It is then predicted a collision free space
craft separation and it will be experienced in the flight.
A) MECHANICAL SYSTEMS
1. Ball & lock systems
Ball & lock system consists of upper & lower stages adopter rings held together by steel
Balls which in turn are held by a retainer ring. The retainer ring is provided with escape
holes for balls.
In the locked condition, the holes in the retainer ring are given an angular offset. During
release, pyro-thrusters rotate the retainer ring which nullifies the offset. The pyro thrusters
are initiated by pressure cartridges an electrical command from the central sequencer of
the vehicle. A stopper limits retainer ring rotation.
Helical compression springs positioned between the flanges impart the required
differential separation velocity.
The lower stage outer ring is provided with through holes for the balls in the locked
condition and the upper stages adapter ring is provided with conical ball seat, the radial
component of the spring forces pushes the balls outward & releases the inner ring which
ensures a clean separation.
Fig [1] – BALL AND LOCK MECHANISM
Two main pyro release mechanisms employed in multi stage launch vehicles are:
1) FLEXIBLE LINEAR SHAPED CHARGE
FLSC is used in launch vehicles for stages separation especially for lower
stages. The basis components of FLSC separation system is the shaped charge which
consists of a V position over the structural member to be cut. Shaped charges are the
only form of pyrotechnics used not only to control the direction of explosive but also to
concentrate it.
The severance by FLSC is by jetting due to V shaped charge; the total cut is the net effect
of the two phenomenons.
a) Penetration by jet
b) Shock severance
Generally; penetration is about 50% of the total cut with shock induced fracture
accounting for the balance. The separation is achieved by severing the machined end ring
of; the inter stage or by severing the skin of the inter stage for efficient and clean
separation.
FLSC is selected for PSLV & GSLV primarily because of it is large diameter of inter
stages.
The selection of FLSC is primarily governed by the system requirement like
a) Joint rotation
b) Simultaneity
c) Reliability
d) Weight
e) Costs etc.
The FLSC system is simple & reliable. But it generates high levels of shock &
contamination shock level depends on thickness & type of material being cut.
ZIP AND SUPERZIP
The two basic drawbacks of unconfined detonating Cords are the shock and
contamination. To avoid these new design concept of encapsulating the detonating cord
initially in a metal tube and subsequently for flexibility in this confinement in a polymer
tube. This concept is called Zip or Super-Zip. Due to the limitations at high temperatures
about 200 degrees Fahrenheit, a flat thin the stain less tube. With an inner polymer
container this technique is called Super-Zip. This is used in longitudinal and
circumferential joints. Shock is reduced to 1/3rd level. High reliability is achieved through
redundancy and contamination through due to gas is prevented.
JETTISONING DEVICES
These systems have been used to provide the required relative separation velocity to the
separating bodies. Energy required for jettisoning the systems are provide by employing
anyone of the following type of thrusters,
Spring thrusters
Pneumatic thrusters
Rocket thrusters
Choice if the type, number and size of the thrusters depend on mass and velocity with
which the spent stages are to be jettisoned.
The Ejection/Jettisoning system design requirements are;
Imparting a well predictable differential velocity to the separating bodies
Minimum tip off rates and minimum acceleration jump at separation
Long storage life
Survival of extreme high, low temperature and nuclear radiation
No contamination, maintainability and high reliability
Minimum weight and minimum volume
Compatibility with vehicle structure.
No debris and safety
Some of the Jettisoning systems usually employed in launch vehicles are described below:
1. SPRING THRUSTERS
In spring thrusters, springs are packed and compressed to the required energy level. Disc
springs depending or coil springs are employed depending on the jettisoning
requirements; high energies are met with disc springs. The advantage of spring thrusters
is that spring energy characteristics can be evalued prior to the assembly of the system
and once assembled jettisoning spring force is always available for the function. Thus,
separate command is not needed for the actuation and is highly reliable. To draw back
with the spring thrusters is that they are heavier compared to the other types of jettisoning
system. For smaller mass with lower energy requirements spring thrusters is an ideal
choice whereas for large size boosters with higher jettisoning energy requirements their
use is not recommended.
2. ROCKET THRUSTERS
Rocket thrusters are used for jettisoning higher diameter massive boosters where the
associated energy requirements are higher. The advantage of the rocket thrusters is that
it can store much higher energy for a given weight of thrusters.
3. PNEUMATIC THRUSTERS
In this type, the working medium is pressurized nitrogen gas. These thrusters are light in
weight as the working medium is gas. The energy stored depends on the initial pressure
and stroke length and there for by changing the pressure stored energy also can be
varied. The pressure holding characteristics of the rolling diaphragm and joints is the
limiting factor for the stored energy. Pneumatic thrusters do not require separate
command for actuation as the jettisoning force is always available. In all these types the
separation relies on the addition of an auxiliary system for jettisoning the spent
stage. The burn out of spent stage, separation and ignition of the continuing stage are
made sequentially with out coasting in between them. The ongoing stages engine ignites
only after two stages have been separated. Therefore these types are called cold
separation.
In these options the hardware design is simple, relatively steady operation process, less
disturbances no exhaust ports are required and heat insulation is required. However there
can be long no; control duration and reliability is very high.
VENTED INTERSTAGE SEPARATION (HOT SEPARATION)
In the hot or vented interstage separation the adjacent stages are separated by the
impingement of the hot exhaust gas jet from the engine of the ongoing stage. The engine
of the ongoing stage ignites when the two stages are still connected together. This type
of separation is called hot separation or fire in the hole staging. The engine of the
continuing stages is ignited at a time much before the occurrences of burned out stage
separation. Thus, eliminates the need for jettisoning devices to provide the separation
impulse. When the thrust build up of the upper stage reaches some level, the release
mechanism is initiated and physical separate take places. In this case, provision for
venting the exhaust gases from the continuing stage is made in the interstage attached to
the spent stage. This option provides relatively less no control duration, high separation
force and high reliability. Sturdy heat insulation layer should be added on the top of the
lower stage tank to prevent damage due to the high pressure and hot stream of engine
exhaust from the upper stage. However the design of the structure has to consider the
high temperature environment.
Fig [3] – VENTED INTERSTAGE SYSTEM OF GSLV
The hot gas separation system is a passives system. It eliminates the uses of retro and
Ullage rocket system, thus enhances the reliability and hence makes it robust as hot gas
separation system allows the ignition of the ignition of the second stage prior to separation
there is a considerable reduction of the none control duration.