Bi-Propellant Engine Development Proposal
Summary
ERPS is nearing the end of the process of demonstrating the knowledge
and skill to develop, test, and fly a mono-propellant HTP engine. With
working mono-propellant engines, ERPS has the knowledge and skills
necessary to begin development of bi-propellant engines utilizing HTP
and a fuel.
The bi-propellant engine project will be focused on developing engines
that are inexpensive to build, maintain, and use for ERPS vehicles. The
vehicles that this project will support are KISS follow-on vehicles and
possibly a POGO or ReSOAR type vehicle.
The project will utilize processes that help insure proper documentation,
safety, and performance.
The project is broken down into phases. The phases are:
- Project Planning and Specifications
- Design and Engineering
- Prototype Manufacturing
- Testing
- Production
The phases are expected to overlap and iterate through several phases.
Project Deliverables:
- Working knowledge of HTP/Fuel engines
- Engines for KISS 2.x/3.x and POGO/Resoar including "fleet leaders".
- Sufficient documentation such that a person unfamiliar with the project will be able to reproduce our results
- Documentation for regulatory agencies.
Project Resources:
Personell:
- Project Manager,
- lead engineer,
- designers/engineers,
- machinist(s),
- welder,
- assembler(s)
Teams:
- CMT,
- Test,
- IT,
- POGO, ReSOAR & KISS teams.
Project Timeline:
Q1/02 Project Planning, Begin Design
Q2/02 Engineering
Q3/02 Prototype production
Q4/02 Begin Testing
Q2 and Q3/03 Full Testing
Q4/03 Production, deliver engines to POGO and KISS teams
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I. Project Planning and Specifications
Deliverable:
A working set of specifications and a complete project plan for
the development of two bi-prop engine styles. One engine shall be
suitable for testing and possible POGO/ReSOAR use, the other shall
be slightly larger and intended for KISS 2.0 use.
The Project plan will incorporate this document.
Initial proposed specifications for the testing/POGO/ReSOAR engine:
- Use 99% HTP and Jet-A
- Minimal size consistent with ease of production
- Regeneratively cooled
- Capable of at least 600psi chamber pressure
- Produce a sea-level Isp > 265
- Engine shut-off cold gas blowdown (limit heat soakback)
Initial proposed specifications for the KISS type engine:
- Use 99% HTP and Jet-A
- 1500-1800n (338lb - 405lb) thrust
- Regeneratively cooled
- Capable of at least 600psi chamber pressure
- Have a sea-level Isp > 265
- Engine shut-off cold gas blowdown
Resources:
All interested people.
- Project manager,
- Designers,
- machinists/mfg,
- test.
Will need input from following teams:
- CMT,
- Test,
- KISS,
- POGO,
- and IT
Resource planning and scheduling software (Internet based), email list.
Timeline
4 meetings over a 2 month period.
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II. Design and Engineering
Deliverable:
A complete set of technical data, drawings, and documentation for the manufacture of two engine types.
- Concept models/drawing
- Simulation and analysis of flows, combustion, forces, temperatures
- Approval of concept
- Detail drawings, interfaces to test stand and vehicles
- Tank, tube, and valve system design
- Change requests to other working groups for test stand and vehicle interface changes
Resources:
Project manager, lead engineer, other designers/engineers.
CAD software (VariCAD is inexpensive, multi-platform), CAD->CFD translator(s), CFD/other CAE, Display sotware
Timeline:
6 meetings, 3 months, until initial designs ready for mfg.
Thereafter all activity concurrently with other phases.
Designers/engineers expected to work on their own.
Meetings are for updates, insure communications.
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III. Prototype Manufacturing
Deliverable:
Two engines each of the Test/POGO and KISS engines.
- Parts and materials procurement
- Produce cut sheets, toolpaths, CNC (if applicable)
- Cut materials
- Receive outsourced parts
- Weld
- Assembly
Resources:
PM, engineer, machinists (1-2), assemblers(1+), welder.
CAM Software (would be nice!), Web/Email based forms (cut sheets, parts requests, etc.)
Lathe, mill, cutoff or band saw, welder, misc hand tools. (a moderately equiped machine shop)
Parts and materials
Timeline:
1-2 work parties per week, 3 months
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IV. Testing
Deliverable:
Engines demonstrated to work according to spec and testing
fully documented, including photographs, video, engine data, and other test
details. Total firing time for each engine to exceed planned total operational
time for production engines.
- Test plans
- Arrange testing facilities, personnel
- Pre-test meeting
- Test
- 15 sec thrust test (basic test, does engine produce thrust)
- Rapid succession 3-5 sec on off test
- Long duration burn (> 90 sec)
- Variable thrust test (determine practical throttle range)
- Post-test meeting (analysis)
- Post all test results and data
Things to be checked during test:
- Insure engine has minimal vibration
- Insure engine temperature reaches an equilibrium within material constraints
- Insure engine has minimal ablation during run
- Insure proper thrust levels
- Insure proper startup and shutdown sequences and timing
Resources:
CMT, Test teams.
PM, engineer(s), test personnel.
HTP (~1500lbs), Jet-A or other fuel(~200lbs), Nitrogen (10 large bottles)
Test stand equipment
Timeline:
1-2 tests/month 6-12 testing months (Note that winter weather may interfere
with testing)
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V. Production
Deliverable:
6 POGO style engines to be integrated into POGO/ReSOAR.
3 or more KISS engines to be integrated into KISS 2.0 and KISS 3.0
- Repeat Item IV process.
- Multiple tests, 1 hour total firing time.
Resources:
Same as III and IV.
Timeline:
1-2 work parties/week, 3months, 1-2 tests/month 3 months.
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