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Rocket Program Handbook Suborbital Projects and Operations Directorate Sounding Rockets Program Office National Aeronautics and Space Administration Goddard Space Flight Center Wallops Flight Facility Wallops Island, Virginia 23337 July 2001 i Preface This Handbook describes the capabilities of the Sounding Rocket program, the design and technology applications used by that program, and the processes established to integrate the customer (principal investigator/program user/scientist/experimenter) into the mission team to ensure the highest probability of a successful project. Neither the United States Government nor any person acting on the behalf of the Unites States Government assumes any liability resulting from the use of information contained in this document or warrants that the use will be free from privately owned rights. The use of a company name does not imply approval or recommendation of the product to the exclusion of others that may also be suitable. ii SOUNDING ROCKET PROGRAM HANDBOOK TABLE OF CONTENTS PREFACE SECTION 1: THE NASA SOUNDING ROCKET PROGRAM (NSRP) 1 1.1 THE PROGRAM: 1959 - THE PRESENT 1 1.2 NASA ORGANIZATIONAL RESPONSIBILITIES 2 1.2.1 PROGRAM MANAGEMENT 3 1.2.2 SOUNDING ROCKET WORKING GROUP (SRWG) 3 1.3 SOUNDING ROCKET PROGRAM CUSTOMER’S ROLE 3 1.3.1 PHILOSOPHY 3 1.3.2 PAYLOAD AND INSTRUMENTATION 4 1.4 SOUNDING ROCKET PROJECT SUPPORT ELEMENTS 4 1.4.1 PROGRAM-PROVIDED SUPPORT SERVICES 5 SECTION 2: THE SOUNDING ROCKET FLIGHT PROJECT 12 2.1 THE MISSION INITIATION CONFERENCE (MIC) 13 2.2 THE REQUIREMENTS DEFINITION MEETING (RDM) 16 2.3 THE DESIGN REVIEW (DR) 16 2.4 PAYLOAD FABRICATION AND PRE-INTEGRATION TESTING 19 2.5 PRE-INTEGRATION REVIEW 19 2.6 PAYLOAD INTEGRATION AND TESTING 20 2.6.1 PRE_INTEGRATION CHECKOUT 20 2.6.2 PAYLOAD INTEGRATION 21 2.6.3 ACCEPTANCE TESTING 21 2.6.4 WAIVERS 21 2.6.5 FINAL CHECKOUT 22 2.6.6 INTEGRATION AND TEST SCHEDULING 22 iii 2.7 MISSION READINESS REVIEW (MRR) 22 2.8 LAUNCH OPERATIONS 23 2.8.1 FLIGHT REQUIREMENTS PLAN 23 2.8.2 OPERATIONS AND SAFETY DIRECTIVE (OSD) 24 2.8.3 OPERATIONAL SAFETY 24 2.9 POST-LAUNCH ACTIVITIES 24 2.9.1 QUICK LOOK REPORTS 24 2.9.2 PRELIMINARY POST-FLIGHT REPORT 24 2.9.3 CUSTOMER'S WRITTEN RESPONSE 25 2.9.4 POST FLIGHT CONFERENCE 25 2.9.5 POST FLIGHT DATA 25 2.10 MISSION SUCCESS/FAILURE 25 2.10.1 ANOMALY INVESTIGATION BOARD (AIB) 26 2.10.2 IN-FLIGHT ANOMALIES 26 2.10.3 AIB ACTION ITEM - RECOMMENDATION IMPLEMENTATION TEAM 26 2.11 THE MISSION CLOSE-OUT REPORT 27 SECTION 3: SOUNDING ROCKET LAUNCH VEHICLES & PERFORMANCE CAPABILITIES 28 3.1 NASA MISSION DESIGNATION SYSTEM 28 3.2 NASA SOUNDING ROCKETS 28 3.2.1 PERFORMANCE CHARACTERISTICS 28 3.3 BOOST GUIDANCE SYSTEMS (BGS) 32 3.3.1 OPERATION OF THE S-19 BOST GUIDANCE SYSTEM 33 SECTION 4: SOUNDING ROCKET PAYLOAD DESIGN CONSIDERATIONS 35 4.1 PAYLOAD DESIGN 35 4.2 FLIGHT PERFORMANCE 36 4.2.1 MECHANICAL LOADS AND VIBRATION 36 4.2.2 THERMAL CONSIDERATIONS 37 iv 4.2.3 VACUUM AND OUT-GASSING 37 4.2.4 AERODYNAMIC DESIGN FACTORS 38 4.3 OTHER PAYLOAD DESIGN CONSIDERATIONS 38 4.3.1 ACCESSIBILITY 38 4.3.2 AVAILABILITY OF PARTS 38 4.3.3 DYNAMIC BALANCE 38 4.3.4 COST 38 4.3.5 REDUNDANCY 38 4.3.6 WEIGHT 39 4.3.7 TESTING 39 SECTION 5: PAYLOAD SYSTEMS 40 5.1 TELEMETRY SYSTEMS 40 5.1.1 DATA TRANSMISSION SYSTEMS 41 5.1.2 PCM/FM SYSTEMS 41 5.1.3 SPARCS (WFF87) ENCODER SYSTEMS 42 5.1.4 FM/FM SYSTEMS 42 5.1.5 PCM VERSUS FM 42 5.2 ATTITUDE INSTRUMENTATION SYSTEMS 43 5.2.1 MAGNETOMETER 43 5.2.2 ATTITUDE GYROSCOPE 44 5.2.3 SOLAR/LUNAR SENSORS 44 5.2.4 HORIZON SENSOR 45 5.2.5 TELEVISION CAMERAS 45 5.2.6 FILM CAMERAS 45 5.2.7 RATE SENSOR 45 5.3 TRANSMITTERS 46 5.4 COMMAND SYSTEMS 46 v 5.5 TELEMETRY ANTENNAS 47 5.6 INSTRUMENTATION AND EXPERIMENT POWER SUPPLY 47 5.6.1 SILVER ZINC CELLS 48 5.6.2 NICKEL CADMIUM 48 5.6.3 VOLTAGE OUTPUT 48 5.6.4 HEATERS 49 5.6.5 SWITCHING 49 5.6.6 PYROTECHNIC POWER SUPPLY 49 5.7 IN-FLIGHT EVENT TIMING SYSTEMS 49 5.7.1 MECHANICAL TIMERS 49 5.7.2 ELECTROMECHANICAL TIMERS 49 5.7.3 ELECTRONIC TIMERS 50 5.7.4 BAROMETRIC SWITCHES 50 5.8 TRACKING SYSTEMS 50 5.8.1 RADAR TRANSPONDERS 50 5.8.2 GLOBAL POSITIONING SYSTEM (GPS) 51 5.8.3 MAGNETIC CALIBRATION FACILITY 52 5.9 MECHANICAL SYSTEMS AND MECHANISMS 52 5.9.1 NOSE CONES 52 5.9.2 STRUCTURES AND SKINS 53 5.9.3 VACUUM DOORS 53 5.9.4 DEPLOYMENT MECHANISMS 53 5.9.5 VACUUM/WATER SEALING 53 5.9.6 MISCELLANEOUS HARDWARE 53 5.9.7 DESPIN SYSTEMS 53 5.10 RECOVERY SYSTEMS 54 5.10.1 LAND 54 vi 5.10.2 WATER 54 5.10.3 RECOVERY AIDS 54 5.11 HIGH ALTITUDE DECELERATORS 55 5.12 ATTITUDE CONTROL SYSTEMS 55 SECTION 6: THE SOLAR POINTING ATTITUDE ROCKET CONTROL SYSTEM (SPARCS) 57 6.1 SPARCS ATTITUDE CONTROL SYSTEM AND COMMAND UP-LINK 58 6.1.1 TARGETING 58 6.1.2 ACCURACY 58 6.1.3 SIZE/WEIGHT 58 6.1.4 AIRBORNE REAL-TIME COMMAND UPLINK 58 6.1.5 SPARCS COMMAND SYSTEMS (SCS) 59 6.2 INSTRUMENTATION (TELEMETRY) 59 6.3 THE WSMR PAYLOAD INTEGRATION FACILITIES 60 6.3.1 THE VIBRATION FACILITY 60 6.3.2 DYNAMIC BALANCE (ON MRC CORPORATION MACHINE) 60 6.3.3 MOMENT OF INERTIA - PITCH/YAW & ROLL 61 6.3.4 CENTER OF GRAVITY - PITCH/YAW & ROLL 61 6.3.5 BEND TEST 62 6.3.6 VACUUM SYSTEMS 62 6.3.7 MAGNETIC CALIBRATION FACILITY 62 6.3.8 DARK ROOM 62 6.3.9 FACILITY (N-200) CLEANLINESS 62 6.3.10 TARGETING 63 6.3.11 OPTICS CAPABILITIES 63 SECTION 7: ENVIRONMENTAL TESTING POLICIES 64 7.1 GENERAL REQUIREMENTS 64 7.1.1 QUALIFICATION TESTING 64 vii 7.1.2 ACCEPTANCE TESTING 64 7.1.3 PRINCIPAL INVESTIGATOR TESTING 64 7.1.4 TEST PLAN 64 7.2 TESTING EQUIPMENT AND CAPABILITIES 65 7.2.1 MASS PROPERTIES MEASUREMENT SYTEMS WFF/WSMR 65 7.2.2 STATIC AND DYNAMIC BALANCING MACHINE (WFF) 66 7.2.3 SHAKERS (WFF/WSMR) 67 7.2.4 VACUUM CHAMBERS (WFF/WSMR) 68 7.2.5 BEND TEST FIXTURES (WFF/WSMR) 70 7.2.6 SPIN DEPLOYMENT AND SEPARATION EQUIPMENT WFF 70 7.2.7 CENTRIFUGE MACHINE (WFF) 71 7.2.8 MAGNETIC TEST FACILITY (WFF) 71 7.2.9 SPIN BALANCE FACILITY (WFF) 72 7.3 PAYLOAD TESTING 74 7.3.1 STATIC AND DYNAMIC BALANCE 74 7.3.2 BEND TEST 74 7.3.3 MASS PROPERTIES 75 7.3.4 VIBRATION 75 7.3.5 WAIVERS 78 7.3.6 TEST TIMES 78 7.4 COMPONENT TESTING 78 SECTION 8: NASA/GSFC/WFF SAFETY POLICY AND RESPONSIBILITIES 79 8.1 SAFETY POLICY 80 8.2 THE RANGE SAFETY ORGANIZATION 81 8.2.1 SAFETY RESPONSIBILITIES OF THE MISSION MANAGER 81 8.2.2 SAFETY RESPONSIBILITIES OF THE PRINCIPAL INVESTIGATOR 82 8.3 GROUND SAFETY PLAN 83 viii 8.4 FLIGHT SAFETY PLAN 84 8.4.1 IMPACT CRITERIA 84 8.4.2 OVERFLIGHT CRITERIA 85 8.4.3 FLIGHT TERMINATION CRITERIA 85 8.4.4 FLIGHT TERMINATION SYSTEM DESIGN REQUIREMENTS 85 8.4.5 FLIGHT PLANNING CRITERIA 85 8.4.6 RANGE CLEARANCE CRITERIA FOR GSFC/WFF LAUNCH RANGE 85 8.4.7 OPERATIONAL PROCEDURES 86 8.5 SAFETY ANALYSIS REPORT 86 SECTION 9: LAUNCH OPERATIONS 87 9.1 LAUNCH RANGES 87 9.2 LAUNCH OPERATIONS 89 9.2.1 RULES TO REMEMBER 89 9.2.2 ROLE OF THE MISSION MANAGER 90 9.2.3 THE FLIGHT REQUREMENTS PLAN 90 9.2.4 TEST AND EVALUATION 90 9.2.5 THE FIELD SCHEDULE 90 9.2.6 THE PREFLIGHT CONFERENCE 91 9.2.7 RECOVERY 91 9.2.8 POST-FLIGHT CONFERENCE 91 9.3 FOREIGN RANGES 91 9.3.1 EXPERIMENTAL TECHNIQUES 92 9.3.2 TRAVEL & LODGING 92 9.3.3 ACCESS 92 9.3.4 FOREIGN NATIONALS 92 9.3.5 EXPORT CONTROL 93 9.3.6 POSTAL SERVICE 93 ix 9.3.7 SHIPPING 93 9.4 MOBILE RANGE OPERATIONS 93 9.4.1 REMOTE LOCATIONS 97 9.4.2 HARSH ENVIRONMENT 97 9.4.3 LIMITED TECHNICAL FACILITIES 97 9.4.4 LIMITED COMMUNICATIONS 98 SECTION 10: DATA PROCESSING AND ANALYSIS 99 10.1 COMPUTER SYSTEMS 99 10.1.1 REAL TIME COMPTUER SYSTEM (RTCS) 99 10.1.2 DATA REDUCTION COMPUTER SYSTEM (DRCS) 99 10.1.3 ENGINEERING COMPUTER SYSTEM (ECS) 100 10.1.4 LAUNCH STATUS REVIEW SYSTEM (LSRS) 100 10.1.5 SPECIAL PURPOSE COMPUTERS 101 10.1.6 DIGITAL TELEMETRY FACILITY 101 10.2 OBTAINING DATA PROCESSING AND ANALYSIS SUPPORT 101 10.2.1 FLIGHT REQUIREMENTS PLAN (FRP) 101 10.2.2 INSTRUMENTATION (TELEMETRY) 102 10.2.3 NON-STANDARD USER REQUIREMENTS 102 10.2.4 POSITIONAL DATA POLICY 102 10.2.5 DATA DISSEMINATION 102 10.2.6 DATA RETENTION 103 SECTION 11: WALLOPS FLIGHT FACILITY 104 11.1 WFF SOUNDING ROCKET PROGRAM SUPPORT FACILITIES 106 11.1.1 ENGINEERING SUPPORT FACILITIES 107 11.1.2 PAYLOAD INTEGRATION LABORATORY 107 11.1.3 ENVIRONMENTAL TESTING LABORATORY 108 11.14 PAYLOAD CONSTRUCTION 111 x 11.1.5 COMPUTER SUPPORT 112 11.1.6 RANGE OPERATIONS 112 11.2 WORKING AT WALLOPS – RULES, REGULATIONS, AND LOGISTICS 114 11.2.1 ACCESS 114 11.2.2 ACCOMMODATIONS 114 11.2.3 WFF - SAFETY RULES AND REGULATIONS 116 11.2.4 SHIPPING/RECEIVING & TRANSPORTATION OF SOUNDING ROCKET COMPONENTS 117 11.3 FOREIGN NATIONALS 118 APPENDICES APPENDIX A: PRINCIPAL INVESTIGATOR'S DATA PACKAGE FOR MISSION INITIATION CONFERENCE (MIC) A-120 APPENDIX B RDM DATA PACKAGE B-123 APPENIX C PRINCIPAL INVESTIGATOR'S DATA PACKAGE FOR A DESIGN REVIEW C-129 APPENDIX D PRINCIPAL INVESTIGATOR'S DATA PACKAGE FOR A MISSION READINESS REVIEW D-130 APPENDIX E PRELIMINARY POST-FLIGHT REPORT OUTLINE E-132 APPENDIX F NASA SOUNDING ROCKET DESCRIPTIONS AND FLIGHT PERFORMANCE CHARACTERISTICS F-135 F.1 SUPER ARCAS LAUNCH VEHICLE (15.XXX) F-136 F.2 BLACK BRANT V LAUNCH VEHICLE (21.XXX) F-138 F.3 NIKE-BLACK BRANT V B/C LAUNCH VEHICLE (27.XXX) F-141 F.4 TERRIER-MALEMUTE LAUNCH VEHICLE (29.XXX) F-144 F.5 ORION LAUNCH VEHICLE (30.XXX) F-146 F.6 NIKE-ORION LAUNCH VEHICLE (31.XXX) F-148 F.7 TAURUS-ORION LAUNCH VEHICLE (33.XXX) F-150 F.8 BLACK BRANT X LAUNCH VEHICLE (35.XXX) F-152 xi F.9 TERRIER-BLACK BRANT VC LAUNCH VEHICLE (BLACK BRANT IX, 36.XXX) F-154 F.10 VIPER DART LAUNCH VEHICLE (37.XXX) F-159 F.11 BLACK BRANT XI LAUNCH VEHICLE (39.XXX) F-162 F.12 BLACK BRANT XII LAUNCH VEHICLE (40.XXX) F-165 F.13 TERRIER-IMPROVED ORION (41.XXX) F-168 F.14 TERRIER LYNX (42.XXX) F-170 APPENDIX G PCM/FM AND FM/FM TELEMETRY SYSTEMS G-172 G.1 VECTOR MMP-900 PCM SYSTEM G-172 G.2 SPARCS AND THE PSL WFF87 ENCODER SYSTEMS G-173 G.3 WFF93 ENCODER SYSTEM G-173 G.4 FM/FM TELEMETRY SYSTEMS G-174 APPENDIX H COMPARISON AND PERFORMANCE OF VARIOUS BATTERY SYSTEMS H-176 APPENDIX I ATTITUDE CONTROL SYSTEMS I-179 I.1 ATTITUDE CONTROL SYSTEM OVERVIEW I-179 I.2 NSROC SOLAR POINTING ATTITUDE ROCKET CONTROL SYSTEM (VII) I-179 I.3 SPACE VECTOR CORPORATION (SVC) INERTIAL ACS I-184 I.4 SVC MAGNETIC ACS I-188 I.5 SVC RATE CONTROL SYSTEM I-191 I.6 AEROJET MARK VI ACS I-195 I.7 AEROJET MARK VID ACS I-199 APPENDIX J GSFC/WFF SAFETY DATA REQUIREMENTS J-205 PAYLOAD DESCRIPTION DATA/HAZARDOUS MATERIALS J-205 PAYLOAD DESCRIPTION DATA/RADIOACTIVE MATERIALS J-206 APPENDIX K SOUNDING ROCKET LAUNCH RANGES K-208 K.1 U.S. ARMY WHITE SANDS MISSILE RANGE K-208 K.2 POKER FLAT RESEARCH RANGE K-212 xii K.3 ANDØYA ROCKET RANGE, NORWAY K-215 K.4 ESRANGE, SWEDEN K-218 APPENDIX L: WALLOPS FLIGHT FACILITY DIGITAL TELEMETRY SYSTEM L-221 APPENDIX M: RADAR DATA FORMAT M-224 APPENDIX N MISSION MANAGER AND SUPPORT SECTIONS (APPROVAL FOR SOUNDING ROCKET MISSIONS) N-225 ACRONYM LIST 235 xiii LIST OF FIGURES FIGURE 2-1 TYPICAL SOUNDING ROCKET MISSION LIFE CYCLE 14 FIGURE 2.4-1 THE PFAFF PAYLOAD USED EXTENDED BOOMS TO INVESTIGATE SPORADIC E EVENTS IN THE IONOSPHERE 19 FIGURE 2.4.2 MENTORED BY NSROC STAFF, UVA STUDENTS BEGIN ELECTRICAL WIRING OF THEIR PAYLOAD AT WFF 19 FIGURE 3.2-1 NASA SOUNDING ROCKET LAUNCH VEHICLES 30 FIGURE 3.2.1-1 NASA SOUNDING ROCKET VEHICLE PERFORMANCE GRAPH 31 FIGURE 3.3.1-1A S-19 BOOST GUIDANCE SYSTEM 33 FIGURE 3.3.1-1B S-19 BOOST GUIDANCE SYSTEM 33 FIGURE 3.3.1-2 DS-19 BOOST GUIDANCE SYSTEM 34 FIGURE 5-1 PFAFF PAYLOAD 21.126 WITH BOOMS EXTENDED 40 FIGURE 5.1.1-1 TYPICAL WFF-93 PCM ENCODER 42 FIGURE 5.2.2-1 MIDAS ATTITUDE SENSOR 44 FIGURE 7.2.1-1 AIRDYNE MARK 8 MASS PROPERTIES MEASUREMENT SYSTEM 66 FIGURE S.2.2-1 GISHOLT ROCKET BALANCING MACHINE AT WFF 66 FIGURE 7.2.3-1 LING ELECTRONICS B335 THRUST AXIS SHAKER AT WFF 68 FIGURE 7.2.4-1 PV/T VACUUM CHANGER AND TENNEY SPACE SIMULATION SYSTEM THERMAL VACUUM CHAMBER AT WFF 69 FIGURE 7.2.5-1 BEND TEST FIXTURE AT WFF 70 FIGURE 7.2.6-1 SPIN DEPLOYMENT CHAMBER AT WFF 71 FIGURE 7.2.7-1 GENISCO CENTRIFUGE MACHINE AT WFF 71 FIGURE 7.3.4-1 NEW OR MODIFIED PAYLOAD VIBRATION TESTING FLOWCHART 76 FIGURE 7.3.4-2 REFLY PAYLOAD VIBRATION TESTING FLOW CHART 76 FIGURE 9.1-1 SOUNDING ROCKET LAUNCH SITES WORLDWIDE 89 FIGURE 9.3-1 RANGE FACILITEIS AT WOOMERA, AUSTRALIA 92 FIGURE 9.4-1 MILITARY LAUNCH AT WSMR 94 xiv FIGURE 9.4-2 RANGE SUPPORT OPERATIONS IN SONDRE STROMFJORD, GREENLAND 96 FIGURE 9.4-2A EXTREME CONDITIONS: SONDRE STROMFJORD, GREENLAND 96 FIGURE 9.4-2B OBSERVATIONS: NORTHERN LIGHTS AT SONDRE STROMFJORD, GREENLAND 96 FIGURE 9.4-3 BLACK BRANT IV PAYLOAD IN WOOMERA, AUSTRALIA 97 FIGURE 11-1 WALLOPS FLIGHT FACILITY MAP 104 FIGURE 11-2 WALLOPS MAIN BASE 105 FIGURE 11-3 WALLOPS ISLAND 105 FIGURE 11-4 WALLOPS MAINLAND 106 FIGURE 11.1.2-1 PLASMA PHYSICS PAYLOAD DURING PAYLOAD INTEGRATION 107 FIGURE 11.1.2-2 ASTROPHYSICS PAYLOAD DURING PAYLOAD INTEGRATION 108 FIGURE 11.1.3-1 ASTROPHYSICS PAYLOAD UNDERGOING LATERAL VIBRATION TESTING 109 FIGURE 11.1.4-1 WALLOPS FLIGHT FACILITY MACHINE SHOP – ELECTRICAL SECTION 112 FIGURE 11.1.4-2 A NOSE CONE IS STREAMLINED IN THE MACHINE SHOP 112 FIGURE 11.1.6-1 WFF FIXED RADAR SYSTEM 113 FIGURE F.1-1 SUPER ARCAS LAUNCH VEHICLE | 
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