Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - SMILE (SMILE - SMall Innovative Launcher for Europe)

Teaser

With an expanding market for small satellites, the need for a dedicated launch service for small satellites has led to many initiatives, most of them outside Europe. The establishment of an independent European launch service provider for small satellites fits the European...

Summary

With an expanding market for small satellites, the need for a dedicated launch service for small satellites has led to many initiatives, most of them outside Europe. The establishment of an independent European launch service provider for small satellites fits the European space strategy, giving an economical impulse for European SMEs. To obtain independent access to space for small satellites, corresponding European technology is necessary. Likewise, a Europe-based launch facility can be considered a strategic asset. Europe’s only existing spaceport is the Centre Spatial Guyanais in Kourou, French Guyana. The services offered there, however, are not suited for start-ups seeking a quick and affordable launch. An alternative is the Andøya Space Centre (ASC) in northern Norway, which is now used for sounding rockets. The project “SMall Innovative Launcher for Europe” (SMILE) aims at designing a small launcher for satellites up to 70 kg and demonstrating critical technologies on propulsion, structures, and avionics to increase the technology readiness level. The second objective is to design a European-based launch facility. The last objective is dedicated to business development and economic viability.

Work performed

Regarding the business development part of work package WP6, NLR, ISIS, and BoesAdvies worked on the small satellite market (opportunity) and the competitors (threats). The business development includes a technology roadmap, the launch service organisation, and a financial plan. A detailed assessment of the market(by mass vs orbit altitude, by inclination, etc.) was performed and historical data were used to extrapolate trends and percentages that were then applied against forecasts for total launch demand for small satellites. A cost-benefit analysis tool was developed, where an initial estimation for recurrent costs showed economic feasibility for an 80 kg launch capacity to a 500 km orbit.

In the launcher design work package (WP1), the requirements were defined by the Design Steering Group (DSG) consisting of NLR, NAMMO, and DLR. Several configurations were defined and analysed by the Concurrent Design Team (NLR, NAMMO, DLR, INCAS, Heron Engineering) using a multi-disciplinary scaling tool. INCAS developed a trajectory optimization tool with a genetic algorithm and an aerodynamics module to assess the maximum possible payload mass. The results predict a payload capacity of 80 kg to 500 km SSO for the hybrid launcher and 130 kg for the liquid launcher.

Regarding Critical Engine Technology (WP2), DLR worked on preliminary design of the propulsion components (feed system, injector, thrust chamber, thrust vector control) for their liquid engine using oxygen and kerosene. The reusable engine contains a film-laying and transpiration cooling system. The injector was based on double swirl coaxial injection elements. DLR manufactured two versions of the assemblies: one with a fully regenerative, water-cooled combustor and a second with a ceramic-based inner liner. 3D Systems provided injectors for the high-pressure testing condition via Additive Laser Manufacturing (ALM) technique. PLD Space designed and set up a test bench that is able of providing high-pressure conditions at the required mass flow rates. In July 2017, the two assemblies were tested at PLD Space. NAMMO developed a design tool for extrapolating design parameters of the hybrid engine to aid the preliminary sizing of the launcher in WP1. NAMMO also worked on improving the existing Unitary Motor, such as longer burn-time, and dry mass reduction. WEPA-Technologies designed the turbopumps based on a common set-up using a gas-generator to drive the turbine, which in turn drives the pumps.

Regarding WP3 Critical Structures Technology, NLR and Airborne selected possible candidates for composite launcher structures, based on costs, performance, availability, and track record. Innovative new approaches such as Out-Of-Autoclave processes and automated manufacturing technology options such as Automated Fibre Placement, Automated Tape Laying, and Pick & Place Robotics are considered to reduce costs. Tecnalia performed a literature study into launcher fairings and looked into materials for high-temperature applications. Heron Engineering used Finite Element Models to analyse load cases representing various flight phases of the launchers, including metal versus composites, monolithic versus honeycomb sandwich, common separation systems, engine thrust frames, and tanks. ISIS generated a design for a MicroSatellite Separation System (M3S), which should be flexible and adaptable, have a standard mechanical interface, and be low cost, modular, and safe to use with a minimum amount of time and tools.

In WP4 Critical Avionics Technology, NLR, Terma, and DLR MoRaBa listed the required functionality and available COTS systems and components, such as gyroscopes and on-board computers. The architecture of the avionics was finalised after internal discussions between NLR, Terma, DLR MoRaBa and ISIS. Besides the architecture, a failure analysis for the avionics was performed and the conceptual EGSE design was defined. As the product line for fibre-optic gyroscopes from NEDAERO (NL) was

Final results

Progress is related to the technology readiness level of the engines including turbo-pumps, the use of automated manufacturing methods (ATL, AFP, ALM) for structural parts, and the use of COTS components for the avionics. Tools such as advanced simulators and test facilities, were developed as well as prototypes for demonstration purposes. The existence of such European small launcher technology is needed to achieve independent access to space for small satellites. With Europe being able to offer cost-effective small launcher services, a significant growth of the European space industry can be expected, providing an opportunity for further international co-operation between companies, research establishments, and SMEs. The recovery of the first stage and reuse of the engines and turbo pumps fits into a circular economy, improving European competitiveness in cost-effective re-usability technologies for space transportation systems. The use of green propellants reduces the impact of an orbital launch on the environment, thus increasing compliance with the evolution of the regulatory framework (REACH). Other benefits for society include an increased interest of the public in engineering and science sectors, leading to additional educational opportunities.

Website & more info

More info: http://www.small-launcher.eu.