| Cover |
1 |
| Title Page |
3 |
| Preface |
5 |
| Table of Contents |
7 |
| TOC This Volume |
11 |
| Section 1 Introduction |
26 |
| Section 2 Summary |
32 |
| 2.1 Task 1 - Prelimary Design |
32 |
| 2.1.1 Control Analysis |
32 |
| 2.1.2 Thermal/Structural Analysis |
34 |
| 2.1.3 Design Options and Groundrules for Task 2 Concept Definition |
36 |
| 2.2 Task 2 - Concept Definition |
40 |
| 2.2.1 Mission Analysis |
40 |
| 2.2.2 Antenna Structural Definition |
40 |
| 2.2.3 Configuration Analysis |
45 |
| 2.2.4 Assembly |
52 |
| 2.2.5 Cost |
62 |
| 2.3 Recommendations |
64 |
| Section 3 Technical Discussion |
68 |
| 3.1 Mission Analysis |
68 |
| 3.1.1 SSPS Configuration and Flight Mode Descriptions |
68 |
| 3.1.2 Transportation System Performance |
68 |
| 3.1.3 Altitude Selection |
75 |
| 3.1.4 SEPS (Ion Engine) Sizing |
81 |
| 3.2 Antenna Structural Concept |
88 |
| 3.2.1 General Arrangement |
88 |
| 3.2.2 Rotary Joint |
88 |
| 3.2.3 Primary/Secondary Antenna Structure |
102 |
| 3.2.4 Structure/Waveguide Interface |
102 |
| 3.2.5 Antenna Weight and Mass Properties |
12 |
| 3.3 Configuration |
122 |
| 3.3.1 Control Analysis |
122 |
| 3.3.2 Thermal Evaluation |
130 |
| 3.3.3 Structural Analysis |
162 |
| 3.4 Assembly And Packaging |
178 |
| 3.4.1 Detail Parts |
178 |
| 3.4.2 Structural Assembly |
186 |
| 3.5 Cost |
206 |
| 3.5.1 Task 1 - Preliminary Design Results |
206 |
| 3.5.2 Task 2 - Concept Definition Results |
210 |
| 3.5.3 MPTS Structural Costs |
224 |
| Section 4 Technology Issues |
230 |
| 4.1 Control System |
230 |
| 4.1.1 Evaluation of Alternate Power Transfer and Drive Devices |
230 |
| 4.1.2 Detailed Control System Analysis |
231 |
| 4.2 Structural System |
232 |
| 4.2.1 Composite Structures and Assembly Techniques |
232 |
| 4.2.2 Tension Brace Antenna Feasibility Assessment |
233 |
| 4.2.3 Local Crippling Stress Evaluation |
233 |
| 4.2.4 Design Environments |
234 |
| 4.2.5 Optimum Antenna Structures |
234 |
| 4.2.6 Finite Element Model Development |
235 |
| 4.2.7 Composite Waveguide |
235 |
| 4.3 Thermal System |
236 |
| 4.31 Maximum Temperature |
236 |
| 4.3.2 Transient Analysis |
237 |
| 4.4 Assembly |
238 |
| 4.4.1 Assembly Cost |
238 |
| 4.4.2 Man's Role in Assembly and Maintenance |
239 |
| Section 5 Conclusions and Recommendations |
242 |
| 5.1 Conclusions |
242 |
| 5.2 Recommendations |
243 |
| Section 6 References |
244 |
| Illustrations |
17 |
| Fig. 1-1 Preliminary Design Option Matrix |
28 |
| Fig. 1-2 Task 1 Preliminary Design Study Logic, Mechanical Systems and Flight Operations |
28 |
| Fig. 1-3 Task 2 Concept Definition Study Logic |
29 |
| Fig. 2-1 Control System Requirements |
33 |
| Fig. 2-2 Control System Requirements |
33 |
| Fig. 2-3 Mechanical System Options Recommended for Task 2 Study |
35 |
| Fig. 2-4 Antenna Geometry Tradeoff |
37 |
| Fig. 2-5 Power Level Limitations Due to Material Thermal Properties |
37 |
| Fig, 2-6 Temperature Difference Between Structural Member Located Different Distances above the Antenna Surface |
38 |
| Fig. 2-7 Task 2 Baseline Design Guidelines |
39 |
| Fig. 2-8 Level 1 Assembly Functional Flow |
41 |
| Fig. 2-9 Baseline SSPS |
41 |
| Fig. 2-10 Mission Options |
42 |
| Fig. 2-11 SSPS Orbital Decay Due to Aerodynamic Drag |
43 |
| Fig. 2-12 Antenna Structural Arrangement |
44 |
| Fig. 2-13 Rotary Joint |
46 |
| Fig. 2-14 Structurt/Waveguide Interface |
47 |
| Fig. 2-15 Structural Joints |
48 |
| Fig. 2-16 Comparison of Maximum Temperature and Thermal Gradients |
49 |
| Fig. 2-17 Temperature Difference Between Beam Cap Members Located Different Distances Above Antenna Surface |
51 |
| Fig. 2-18 Waste Heat Flux at Center of Antenna as Function of Scale Factor |
51 |
| Fig. 2-19 Cross-Section Design |
53 |
| Fig. 2-20 Range of Thermally Induced Deflections and Local Slope |
54 |
| Fig. 2-21 Structural Detail Parts Assembly Options |
55 |
| Fig. 2-22 Detail Part Assembly Summary |
55 |
| Fig. 2-23 MPTS Antenna Structural Assembly |
57 |
| Fig. 2-24 Assembly Operations Analysis Approach |
58 |
| Fig. 2-25 Summary of Assembly Options |
59 |
| Fig. 2-26 Transportation and Assembly Elements |
60 |
| Fig. 2-27 Transportation and Assembly System Fleet and Support Equipment Characteristics and Cost Summary (1974 $'s) |
61 |
| Fig. 2-28 Traffic and Fleet Size Summary |
63 |
| Fig. 2-29 Assembly Cost Comparison |
63 |
| Fig. 2-30 Antenna Structural Cost Comparison |
65 |
| Fig. 2-31 Recommendations for Task 3 Study |
65 |
| Fig. 3.1-1 SSPS Baseline Configuration |
69 |
| Fig. 3.1-2 SSPS Mass Properties |
70 |
| Fig. 3.1-3 Mission Options |
71 |
| Fig. 3.1-4 Shuttle Payload Capability - Due East Launch from KSC |
73 |
| Fig. 3.1-5 Shuttle Payload Capability - Due East Launch from KSC |
73 |
| Fig. 3.1-6 Cryogenic Tug Deploy Performance |
74 |
| Fig. 3.1-7 Cryogenic Tug Configuration |
74 |
| Fig. 3.1-8 Ion Propulsion Altitude vs Time from (100 N Mi Circuhr' — No Hane Change |
76 |
| Fig. 3.1-9 SSPS Orbit Decay |
78 |
| Fig. 3.1-10 SSPS Orbit Decay Characteristics |
79 |
| Fig. 3.1-11 SSPS Orbit Decay Characteristics |
79 |
| Fig. 3.1-12 Force Required to Compensate for Air Drag |
80 |
| Fig. 3.1-13 Ion Propulsion System Sizing Factors |
82 |
| Fig. 3.1-14 Optimum Specific Impulse |
84 |
| Fig. 3.1-15 Maximized Payload Ratio |
84 |
| Fig. 3.2-1 Structural Arrangement MPTS Antenna |
90 |
| Fig. 3.2-2 Structural Arrangement MPTS Antenna |
91 |
| Fig. 3.2-3 Gear System |
92 |
| Figure 3.2-4 Typical Motor Options |
94 |
| Fig. 3.2-5 Rotary Drive Concept |
95 |
| Fig. 3.2-6 Antenna Rotary Joint (Frictionless Linear Motor Concept) |
96 |
| Fig. 3.2-7 Power Transfer Device Selection Considerations |
98 |
| Fig. 3.2-8 Brush/Slip Ring Concept |
98 |
| Fig. 3.2-9 Operating Temperatures (°C) of Candidate Brushes |
99 |
| Fig. 3.2-10 Voltage Drop for Candidate Brushes (for Single Contacts |
99 |
| Fig. 3.2-11 Friction and Wear Properties of Oils (Four-Ball Test) |
101 |
| Fig. 3.2-11 Friction and Wear Properties of Oils (Four-Ball Test) |
101 |
| Fig. 3.2-13 Structural Members |
103 |
| Fig. 3.2-14 Waveguide/Structure Interface, Single Point Support |
104 |
| Fig. 3.2-15 Waveguide/Structure Interface, Three Point Support |
104 |
| Fig. 3.2-16 Antenna Structure Weight Summary (Graphite/Epoxy Triangular Hat) |
106 |
| Fig. 3.2-17 Antenna Weight Comparison (Aluminum vs Composites Tubular Section) |
107 |
| Fig. 3.2-18 Antenna Weight Comparison (Aluminum vs Composites Triangular Hat Section) |
107 |
| Fig. 3.2-19 Structure Weight vs Antenna Dimension |
109 |
| Fig. 3.2-20 SSPS Microwave Antenna Mass Properties |
110 |
| Fig. 3.2-21 Antenna Structure Weight |
111 |
| Fig. 3.2-22 Primary Structure (Upper Caps) |
113 |
| Fig. 3.2-23 Primary Structure (Posts) |
114 |
| Fig. 3.2-24 Primary Structure (Lower Caps) |
115 |
| Fig. 3.2-2S Primary Structure Integration Items |
115 |
| Fig. 3.2-26 Secondary Structure |
116 |
| Fig. 3.2-27 Secondary Structure Integration Items |
116 |
| Fig. 3.2-28 Elevation Joint Support |
117 |
| Fig. 3.2-29 Elevation Yoke |
118 |
| Fig. 3.2-30 Azimuth Yoke Support |
119 |
| Fig. 3.2-31 Azimuth Yoke |
120 |
| Fig. 3.2-32 Mechanisms and SupportFig. |
121 |
| Fig. 3.2-33 Rotary Joint Drive (Mechanical vs Linear Induction Motor) |
121 |
| Fig. 3.3-1 System Torque Environment |
123 |
| Fig. 3.3-2 Microwave Antenna Mechanical Pointing System |
124 |
| Fig. 3.3-3 SSPS Bending Mode Data |
126 |
| Fig. 3.3-4 Servomechanism Environment |
127 |
| Fig. 3.3-5 Slip Ring Friction Torque |
129 |
| Fig. 3.3-6 Control System Requirements |
129 |
| Fig. 3.3-7 Preliminary Design Control System |
131 |
| Fig. 3.3-8 Antenna Support Structure |
132 |
| Fig. 3.3-9 Gaussian Radiative Heat Flux from Antenna Surface |
134 |
| Fig. 3.3-10 Maximum Structural Temperature vs Transmitted Power |
135 |
| Fig. 3.3-11 Microwave Power Transmission System Structure |
137 |
| Fig, 3.3-12 Beam Cap Element Geometries |
138 |
| Fig. 3.3-13 Typical Thermal Model for Structural Member |
139 |
| Fig. 3.3-14 Maximum Tube Temperature as a Function of Antenna Surface Temperature with Tube Inner Wall Emissivity as a Parameter |
140 |
| Fig. 3.3-15 Maximum Temperature Difference Across a Tubular Structural Member as a Function of Antenna Surface Temperature with Tube Inner Wall Emissivity as a Parameter |
142 |
| Fig. 3.3-16 Thermally Induced Stresses and Minimum Wall-to-Radius Ratios for Tubes |
142 |
| Fig. 3.3-17 Comparison of Tempertature Profiles In High-Hat Section |
144 |
| Fig. 3.3-18 Temperature Distribution within Triangular Shaped Structural Member |
145 |
| Fig. 3.3-19 Maximum Temperature and Temperature Difference in Triangular Member |
147 |
| Fig. 3.3-20 Comparison of Maximum Temperature for Different Beam Cap Element Geometries |
149 |
| Fig. 3.3-21 Comparison of Maximum Temperature Difference for Various Geometries |
149 |
| Fig. 3.3-22 Temperature Distribution in a Beam Cap Member Located 1 Meter Above Antenna Surface |
150 |
| Fig. 3.3-23 Temperature Distribution in a Beam Cap Member Located 1 Meter Above Antenna Surface |
151 |
| Fig. 3.3-24 Temperature Difference between Beam Cap Members Located Different Distances Above Antenna Surface |
154 |
| Fig. 3.3-25 Temperature Difference Between Beam Cap Members Located Different Distances Above Antenna Surface |
154 |
| Fig. 3.3-26 Column Tempertatures |
157 |
| Fig. 3.3-27 Waste Heat Flux at Center of Antenna as Function of the Scale Factor |
157 |
| Fig. 3.3-28 Waste Heat Profile for Various Values of the Scale Factor |
158 |
| Fig. 3.3-29 Maximum Temperatures as a Function of Scale Factor |
160 |
| Fig. 3.3-30 Thermal Performance of MPTS With and Without Heat Pipes |
161 |
| Fig. 3.3-31 Alternate Structural Arrangements |
163 |
| Fig. 3.3-32 Weight Relationship for Different L/D (Length Tube/Dia meters) |
164 |
| Fig. 3.3-33 Strength of Circular Tubes for Various Axial Compression Loads as Function of Wall Thickness and Diameter |
166 |
| Fig. 3.3-34 Strength of Circular Tubes for Various Axial Compression Loads as Function of Wal I Thickness |
166 |
| Fig. 3.3-35 Tri Beam Cap Cross-Sections (Graphite/Epoxy) |
167 |
| Fig. 3.3-36 Design Loads |
168 |
| Fig. 3.3-37 Deflections - Preliminary Assessment |
168 |
| Fig. 3.3-38 Typical Antenna Deflections Due to Thermal Gradients (40 Meter Beam Depth) |
170 |
| Fig. 3.3-39 Typical Slopes of Structure Due to Thermal Gradients |
170 |
| Fig. 3.3-40 "Egg Crate" Secondary Structure Deflection Slopes (108 Meter Section) |
171 |
| Fig. 3.3-41 Estimated Graphite Composite Properties |
173 |
| Fig. 3.3-42 Thermal Stability of Various Adhesives at 533°K |
173 |
| Fig. 3.3-43 Cost and Processing Characteristics of Various Types of Adhesives |
175 |
| Fig. 3.3-44 Comparison of Material Properties |
175 |
| Fig. 3.4-1 Structural Detail Parts Assembly Options |
179 |
| Fig. 3.4-2 Characteristics of Articulated Lattice Beam |
180 |
| Fig. 3.4-3 T ri-Beam Layout Using Tubular and Solid Element Caps |
181 |
| Fig. 3.4-4 Allowable Column Load |
183 |
| Fig. 3.4-5 Shuttle Compatibility Packaging |
183 |
| Fig. 3.4-6 Inflight Detail Parts Assembly |
184 |
| Fig. 3.4-7 Support Equipment Requirements for In-Flight Assembly of Tri Beams |
185 |
| Fig. 3.4-8 Auto In-Orbit Manufacture (Aluminum) |
185 |
| Fig. 3.4-9 Level 2 Functional Flow : Assemble MPTS |
187 |
| Fig. 3.4-10 Level 3 Functional Flow: Assemble Rotary Joints (Sheet 1 of 3) |
188 |
| Fig. 3.4-11 Level 3 Functional Flow: Assemble Rotary Joint to Antenna Interface Structure |
191 |
| Fig. 3.4-12 Level 3 Functional Flow: Assemble Primary/Secondary Structure |
191 |
| Fig. 3.4-13 Level 4 Functional Flow: Manipulator Module Assembly of Lower Cap; Primary Structure |
193 |
| Fig. 3.4-14 Assembly Timeline and Consumables Requirement |
194 |
| Fig. 3.4-15 Manipulator Performance Complexity Factor |
196 |
| Fig. 3.4-16 Manipulator Module Assembly Operations Summary |
196 |
| Fig. 3.4-17 Level 4 Functional Flow: EVA Assemble Lower Cap; Primary Structure |
198 |
| Fig. 3.4-18 Detailed Task Sequence and Performance Times for Two-Man Skylab 3 Twin-Pole Sunshade EVA Deployment |
199 |
| Fig. 3.4-19 EVA Assembly Operations Summary |
199 |
| Fig. 3.4-20 Free-Flying Teleoperator Concept |
201 |
| Fig. 3.4-21 Low Altitude Assembly Support Equipment Weight and Cost Estimates |
201 |
| Fig. 3.4-22 High Altitude Assembly, Typical 6-Man Support Space Station ConceptFig. 3.4- |
204 |
| Fig. 3.4-23 High Altitude Assembly, Typical 12-Man Support Space Station Concept |
204 |
| Fig. 3.4-24 Typical Manned Transport Module Concept |
205 |
| Fig. 3.5-1 Task I - Preliminary MPTS Design Data Sheet, Rectangular Grid |
208 |
| Fig. 3.5-2 Task I, Preliminary MPTS Design Data Sheet - Radial Spoke |
209 |
| Fig. 3.5-3 Transportation and Assembly Cost Comparison Cases |
211 |
| Fig. 3.5-4 SSPS Weights |
211 |
| Fig. 3.5-5 Traffic Mode! Assessment, Flight Plan 1 |
213 |
| Fig. 3.5-6 Traffic Model Assessment, Flight Plan 3 |
214 |
| Fig. 3.5-7 Level I Functional Flow: Assembly |
214 |
| Fig. 3.5-8 Traffic Model and Fleet Size Assessment, Flight Plan 2 |
216 |
| Fig. 3.5-9 Traffic Analysis Summary |
218 |
| Fig. 3.5-10 Transportation and Assembly Cost, Flight Plan 1 |
218 |
| Fig. 3.5-11 Transportation and Assembly Cost, Flight Plan 2 |
219 |
| Fig. 3.5-12 Transportation and Assembly Cost, Flight Plan 3 |
220 |
| Fig. 3.5-13 Transportation and Assembly System Fleet and Support Equipment Characteristics and Cost Summary (1974 S's) |
221 |
| Fig. 3.5-14 Waveguide Weight and Packaging Density |
223 |
| Fig. 3.5-15 Traffic Requirements as Function of Waveguide Weight and Packaging Density |
225 |
| Fig. 3.5-16 Transportation and Assembly Cost Sensitivity to Waveguide Packaging Density |
225 |
| Fig. 3.5-17 Materials and Processing Costs, $/LB ($/Kg) |
227 |
| Fig. 3.5-18 MPTS Structural Cost Estimate Assumptions |
229 |
| Fig. 3.5-19 MPTS Structural Concept Comparison |
229 |
| List of Non-Standard Terms |
24 |