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Unpressurized Cargo (UPC) - Orion Functional Interface Requirements Document (FIRD)

Prepared by:TBDTBDGreenbelt, MD

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FOREWORD




Table of ContentsSection Page1. Introduction.................................................................................................7

1.1. Purpose and Scope..............................................................................71.2. Precedence...........................................................................................71.3. Responsibility and Change Authority.................................................7

2. Documents...................................................................................................72.1. Applicable Documents........................................................................72.2. Reference Documents.........................................................................7

3. Interfaces.....................................................................................................83.1. General................................................................................................8

3.1.1. Interface Description....................................................................123.1.2. Interface Responsibilities.............................................................133.1.3. Coordinate Systems......................................................................133.1.4. Engineering Units, Tolerances, and Conversions........................14

3.2. Interface Requirements......................................................................153.2.1. Interface Plane..............................................................................15




List of FiguresSection PageFigure 3-1. UPC Separation Support System........Error! Bookmark not defined.Figure 3-2. UPC Extraction Envelope ( per CMG reference study).............Error!

Bookmark not defined.Figure 3-3. UPC-Fixed Single and Multiple Instrument Configurations.......Error!

Bookmark not defined.Figure 3-4. UPC SM Fixed Carrier Configuration................................................25




List of TablesSection PageTable 3-1. Key Design Requirements.................................................................12




Revision Log

Revision Revision Date Page Change Item000 XX Month 2008 All SDR Submittal




1. Introduction1.1. Purpose and Scope. This FIRD defines and controls the interface(s) requirements between the Orion Service Module (SM) and Unpressurized Cargo located inside the SM for the ISS Design Reference Mission (DRM)

1.2. Precedence. The requirements defined within this document are derived from the Constellation Architecture Requirements Document (CARD). The CARD is the controlling document and shall take precedence.

1.3. Responsibility and Change Authority. The Orion Service Module Project Office, Glenn Research Center (GRC), maintains programmatic and engineering control of the Service Module. The Explorations Systems Project, maintains programmatic and engineering control of the UPC carrier hardware and payloads.

1.4. Documents

1.4.1. Applicable Documents CxP-70000, Constellation Architecture Requirements Document (CARD) CxP-70035, Constellation Program Portable Equipment, Payloads, and Cargo

(PEPC) Interface Requirements Document (IRD)

1.4.2. Reference Documents GSFC-STD-7000, General Environmental Verification Standard (GEVS) GSFC - STD – 1000, “Rules for the Design, Development, Verification,

and Operation of Flight Systems“, Revision C.2 - December 12, 2006 CxP-70138, Constellation Level-II Coordinate Systems CxP-70135, Constellation Program Structural Design and Verification

Requirements CxP-70136, Constellation Program Loads Data Book CxP-70143, Constellation Program Induced Environment Design

Specification (IEDS) CxP-70023, Constellation Program Design Specification for Natural

Environments (DSNE) CxP-70036, Constellation Environmental Qualification and Acceptance

Testing Requirements (CEQATR) CxP-70080, Constellation Program Electromagnetic Environmental

Effects (E3) Requirements Document




CxP-70050, Constellation Program Electrical Power System Specification CxP-70031, Constellation Program Orion-to-International Space Station

Interface Requirements Document CxP-72000, Constellation System Requirements for OrionCxP-70077,

Constellation Program Architecture Description Document (ADD) CxP-MOU-20090831-1, Memorandum of Understanding Between

Unpressurized Cargo Exploration Project and the Constellation Program Operations and Test Integration Office on the Crew Exploration Vehicle - Orion Project

UPC-TBD, Orion-UPC Concept Study Report

2. System Description2.1. UPC System DescriptionThe UPC carrier system allows utilization of unused volume within the Orion SM to fly fixed instruments, extractable equipment, and ejectable small subsatellites. It is designed to fit within the volume of the 0-60 degree SM bay, mounted on the forward bulkhead. The Orion spacecraft will provide to UPC, in addition to structural accommodations, two power and data interfaces.

The UPC design will allow for three separate missions to be flown on a common payload adapter fitting (PAF). Three basic payload configurations will be accommodated: fixed payload, extractable payload, and ejectable sub-satellite. The UPC carrier will provide to customer payloads power, command, and data handling for control and monitoring, as well as any thermal control necessary.

Details regarding the UPC system may be found in the UPC Study Report, UPC-TBD.

2.2. Fixed PayloadsThe design of the UPC-Fixed configuration (Figure 2-1) provides a flexible approach to accommodate up to six instruments. A lightweight modular shelf design interfaces with the UPC PAF through a RMSS. This mechanical connection also provides electrical and data connections for the instrument. The modular instrument shelf design and the attachment through the RMSS, simplifies integration and allows off line instrument qualification as a single unit. Each shelf incorporates a thermal radiator with additional radiator area being available just below the UPC volume opening. Modules 3-6 can be configured individually or partitioned into dual- or triple-module configurations.




Figure 2-1: UPC-Fixed Single and Multiple Instrument Configurations.

2.3. Extractable PayloadsThe extractable payload (Figure 2-2) will mount to a deck that will have a RMSS interface. The extractable payload will provide a mechanical interface to a human (EVA) or robotic handling (IVA) connection. Once on station at the ISS, the payload may be attached to the ISS with either the RMSS interface or other attachment hardware that can be provided.




Figure 2-2: Extractable Payload Envelope [show payload]

2.4. Ejectable Sub-Satellites

2.4.1. Ejectable PayloadThe ejectable payload (Figures 2-3 and 2-4) will be a complete, self contained satellite. At an agreed upon time in the mission schedule it will be ejected into an orbit from which it can begin its mission. The deployment will be through the RMSS, and initiated through the SM. The RMSS will retract and kick-off springs will separate the payload from the SM. Kick-off rates for the RMSS are expected to be less than 0.5 deg per 38.81 inches. Payload envelope for this configuration has been calculated to allow for this kick-off rate.




Figure 2-3: Ejectable Payload X-Wing Design [edit/simplify]




Figure 2-4: Ejectable Payload Generic SMEX_LT bus [edit/simplify or combine w/ Fig 2-3]

3. Level-II Interface Requirements 3.1. Requirements Flowdown

UPC requirements flow down from the Constellation Program Level-II requirements, as shown in Figure 3-1. The UPC requirements are considered Level-III requirements.




Figure 3-5: UPC Requirements Flowdown

3.2. CARD Requirements

The Orion SM was specified to accommodate UPC for the ISS DRM as allocated in the CARD. These top-level requirements are consolidated in the table below. The key design requirements and interfaces are discussed in the following sections.




Table 3-1. Key Design Requirements.Parameter

CARD Requirement/Allocation Comment

Orbit ISS Orbit:• inclination = 51.3-51.9 degrees• altitude = 150-248 nmi (342.6-459.3 km)• eccentricity ≤ 0.0081(Appendix A2.0)

SM releases sub-satellite into ISS orbit with onboard propulsion to maintain LEO or transfer to lunar orbit

Duration Orion docked to ISS for at least 210 days (Ex-0012-04)

Sub-satellite 2-5 years operational life

Volume 103 ft3 (2.92 m3) (Ex-0010-08) UPC Common Payload Fixture 32 ft³ [verify]Standard payload volume 101.1 ft³

[verify]Extended payload volume 164.3 ft³

[verify]Mass 600 kg (1,322 lbm) for ISS

missions (Ex-0010-07)Total launch mass allocation onboard SM includes P/L & carrier/ ejection h/w

Power ≤ 400 W via 2 independent, non-mission specific power interfaces (CA5748-PO)

Total allocation (until release) via CEV EPS includes S/C bus and P/L Powered off during launch and ascent

Data Rate

Standard, redundant, non-flight critical data bus interface (CA5749-PO)

Initial TBD Mbps via Orion comm system until release

Thermal (Not defined in CARD for UPC) Maintain survival temps until released

4. Mechanical Interfaces

4.1. Overview UPC will interface with the Orion SM through the existing propellant tank mounting locations. The UPC Payload Attach Fitting (PAF) interface will be through the forward deck, attaching with the existing radial hole pattern that attaches the propellant tank. . The secondary UPC interface will be through the aft propellant deck attachment to the Orion SM structure (deck removed). Orion SM will provide attachment hardware (bolts, washers, etc.).




Figure 3-1: UPC PAFMounting Concept

4.2. Coordinate Systems and Units Coordinates to Orion SM are defined from the circular mounting hole plane on the forward propulsion deck with the X-axis along the Orion launch vector and the Y-axis along the Orion SM wall separating the propulsion tanks.

The UPS coordinate system origin is located at the intersection of the separation plane and center axis of the Rigidizable Motorized Separation System (RMSS) with the X-axis along that vector and the Z-axis opposite the Orion Launch vector (see Figure 3-2).




Figure 3-2: UPC-Orion InterfaceCoordinate System

UPC will adhere to the Orion project decision to use the English form of units. These shall be represented as inches (in), feet (ft), pounds (lbs). Dual dimensions shall be in centimeters (cm) and shall be noted as in/[cm].

4.3. RequirementsIn the subsections that follow, define structural limiting values at the interface, such as interface loads, forcing functions, and dynamic conditions.

4.3.1. Interface Plane Define the interface requirements on each side of the interface plane. [TBD]

4.3.2. EnvelopeThe Orion SM propulsion tank bay provides a total of 132ft³ [verify]. The UPC common Payload Adapter Fitting occupies 31ft³. Two available volumes are left for payloads in the UPC (Figure 3-3). The standard volume is defined as the remaining volume inside the Orion SM bay and is 101.0ft³. The extended volume adds the volume which extends the standard volume to within 2.0 in of the Orion SM fairing dynamic envelope this provides a total volume of 168.3ft³. This volume maximizes UPC payload accommodations.




Figure 3-3UPC Envelope Definition

4.3.3. Mass Properties The total launch mass for UPC (attached or ejected) shall not exceed 1322.0lbs (600 kg). This total does not include mounting hardware and attach points, which are allocated to the SM structure.

The Center of Gravity (CG) is defined at the separation plane of the Rigidizable Motorized Separation System (RMSS) and along this centerline. It is a cylinder 4.0 in lateral by 35.4 in long (TBD) (Figure 3-4).

Figure 3-4 UPC CG Envelope

Center of Mass for UPC ESS is defined as [TBD] point within the body of the ESS.

The Orion-SM shall be capable of a safe Earth reentry with up to 1322.0 lbs (600kg) mass in the UPC bay.

The SM will provide the analysis and resources to insure complete demise of the UPC payload. [Cite as a separate requirement]




4.3.4. Structural

The SM shall provide structural attachment points to accommodate the various UPC configurations.

A common payload attach fitting (PAF) will be used for all UPC options: fixed, extractable, and ejectable. The UPC PAF will mount to the SM at the forward propulsion tank deck utilizing the same mounting holes that mount the propulsion tank to the deck. It will also have attachments to the SM at the fittings that attach the aft propulsion deck (see Figure 3-1). It will incorporate a rigidizable motorized separation system (RMSS) to interface with the payload (Figure 3-5).




Figure 4-5. UPC RMSS Separation Support System.

The SM shall provide an “extraction envelope” or opening to extract the UPC on orbit (Figure 3-6)

Rationale: This envelope preserves CMG ORU transfer and maximizes UPC payload accommodations. A 2.0 in. clearance was maintained for UPC ESS and Extractable Payloads to avoid any possible dynamic/static clearances until Orion SM design and models mature (TBD).




Figure 4-6. UPC Extraction Envelope .

Verify hatch opening dimensions [TBD]

4.4. Typical Payload Configurations [relocate to Sec. 2.1]

4.4.1.




5. Avionics Interfaces 5.1. Overview The Avionics subsystem shall consist of Electrical Power, Command and Data Handling and power/signal distribution. The SM interface to the UPC avionics box will be two power and two data connectors, as shown in Figure 4-1 [add].

Figure 5-6: UPC Avionics Interfaces

The RMSS has a analog power release that is controlled and commanded by the SM. Primary and secondary power and data links are passed through while the mechanism is mated. The SM will provide a low-speed bi-directional data interface and power to the RMSS via break-away connectors on the release mechanism in order to monitor RMSS health and safety prior to RMSS ejection. The RMSS will get power for stay-alive heaters and the collection of house keeping data, with a mixture of SM power and a battery internal to the RMSS.




Verification: A RMSS is intended to be a multiple spacecraft standard that can be easily installed and removed with proper support equipment. The interface can be verified under test and with flight equipment or simulators. [Verifications should be either included elsewhere for consistency, or deleted.]

5.2. Electrical (Power)The electrical power system interface while attached to the Orion Service module will be 120Vdc via two independent interfaces with a power capability up to 400 watts. A mission-specific power loads analysis will determine the actual power available to UPC. The Constellation Architecture shall comply with CxP 70050-01, Constellation Program Electrical Power System Specification, Volume 1: Electrical Power Quality Performance for 120VDC and CxP 70050-02, Constellation Program Electrical Power System Specification, Volume 2: User Electrical Power Quality Performance for 120 VDC.

Prior to launch, Orion will supply UPC power for battery trickle charging while on the pad, up T-TBD [verify]. The UPC will be powered off during launch and ascent phase, and power provided once Orion is power positive on orbit.

A typical timeline for a UPC Ejectable Spacecraft deployment is as follows: [Relocate to a separate mission ops section]


UPC Spacecraft in Service Module to Orbit

0

30

60

90

120

150

180

210

240

270

300

330

360

0 1 2 3 4 5 6 7 8 9 10 Time (Hours)

Pow

er (W

atts

)

0.0000

0.5000

1.0000

1.5000

2.0000

2.5000

3.0000

3.5000

AmpH

ours

Use

d

Instrument #1

ACS

Thermal

SAD

Propulsion

Communications

Avionics

Harness

Total

AmpHour Used



Time lines for Fixed and Extracted Carriers shall be powered to TBD load profile with anticipated power before launch, removal of power during launch and reestablishing of power after Orion solar arrays are deployed and the Orion bus is power positive.

UPC power required will be 300 W max nominal. See Figure XX for typical power profiles.

Interface power may be limited to survival power requirement of TBD watts during transit, safe hold and survival modes.

The UPC will adhere to SM grounding, bonding requirements and surface charge requirements.

The UPC will adhere to SM Electromagnetic Control Plan (EMC).

The UPC may require up to TBD watts for short periods of time to provide circuit protection coordination to the SM requirements.

UPC will be designed to not provide power to the SM bus.

5.3. Command and Data Handling


Time Time (min) (hours) Event Log

1 0.02 Launch2 0.03 First Stage Seperation/ Upper Stage Ignition3 0.05 Service Module Jettision then LAS Jettison9 0.15 Upper Stage Engine Shutdown

10 0.17 Second Stage Seperation then Second Stage seperation Burn15 0.25 Maneuver to Circularize Burn Attitude24 0.40 Circularization Burn29 0.48 Orion Solar Array Deploy44 0.73 Orion High Gaine Antenna Deploy120 2.00 Orion Bus Power avalible to the Free Flyer250 4.17 UPC Spacecraft ejection253 4.22 UPC Solar Arrys Deploy290 4.83 UPC Spacecraft Eclipse320 5.33 UPC Spacecraft Sun380 6.33 UPC Spacecraft Eclipse410 6.83 UPC Spacecraft Sun470 7.83 UPC Spacecraft Eclipse500 8.33 UPC Spacecraft Sun

Orbit Cycle continues



Shall be the intra communications and data flow between the UPC form of a Ejectable spacecraft, Fixed Carrier or a Extractable carrier. [reword/elaborate]Requirements

5.3.1. Power

The UPC Avionics power interface to Orion SM shall be 120 VDC (+/- 10%), 400W maximum, via redundant power feeds from Orion.

The redundant power interface shall be isolated by a minimum of 1 megohm in parallel with 0.1mH and not more than .03 microfarads of mutual capacitance between the two independent power feeds including supply and return lines within the UPC.

The UPC common ground shall be connected to the Orion SM common ground.

The UPC interface to the Orion SM surge current shall be within [TBD] requirements.

The UPC I/F to the Orion primary/redundant input power shall be designed to [TBD] reverse current limits such that there will be no damage to the flight hardware in the event of a hard fault across the power source.

5.3.2. C&DH The UPC Avionics data I/F to Orion SM shall be a 1 Gbite Ethernet. [elaborate]

The UPC Avionics data I/F to ISS Robotic Arm shall require no data interface.

3.2.1.5.3.3 The UPC Avionics data I/F to SM and ISS. The attached payload accommodation site shall accept ISS active UMA on the PAS or UCCAS. The PASS and UCCAS sites are Remote Terminals (RTs) to the Payload Multiplexer-demultiplexer (MDM) which is internal to the USL. All C&DH requirements are a subset of those for the Payload MDM and are derived from the requirements specified in the SSP 57000, Pressurized Payload Interface Requirements Document.

3.2.1.5.4 Electrical Systems. The UPC Electrical System shall control the requirements and supply harnessing and interconnections form various suppliers of power and data for the UPC Ejectable Spacecraft, Fixed Carrier and Extractable carrier. The Electrical Power interface shall be 120vDC power with a Orion data interface of 1 Gbit Ethernet and ISS interface TBD.




3.2.1.5.4.1 Electrical Power interface. The electrical power interface shall be with the RMSS at 120vDC with redundant power feeds of less than 1000 watts. Voltage regulation is to be with in 112.5 to 126 volts DC with transient voltages of 95.5 to 143.1 volts up to 0.60 MS and damping to the regulated voltage band within 0.3 ms.

3.2.1.5.4.2. Circuit protection coordination. The circuit protection and fuse requirements shall be coordinated with the SM and ISS for TBD I2t requirements. Transients due to circuit protection device activation shall be TDB. The UPC I/F to Orion circuit protection shall trip in 25ms when current exceeds 8.33 amps.

3.2.1.5.4.3. Isolation requirements. Isolated lines both power and data shall have minimum of 1 megohm resistance and 0.03 microfarads of capacitance.

The UPC interface to Orion SM shall meet the electrostatic discharge requirements [TBD]

The UPC interface to the Orion SM load impedance shall be [TBD] +/- tolerance.

The UPC interface to the Orion SM shall comply with the EMC/EMI requirements as defined in CxP-70080, Constellation Program Electromagnetic Environmental Effects (E3) Requirements Document.

5.3.2.1. Communication and Data [Merge with C&DH interface section?]After the launch vehicle separation, the Orion Umbilical-1 will support a digital health and safety checkout with UPC before the UPC deploys. The UPC checkouts after deployment can continue in RF with Orion in the payload interrogator mode. Once UPC is safely away from Orion and cleared for UPC operations, then the UPC can become a free flyer using RF for data communications.

The UPC design interfaces Orion via the UPC C&DH Single Board Computer (SBC) for command and telemetry via a Honeywell-developed Time Triggered Gigabit Ethernet (TT-GbE) interface card with a static Media Access Control (MAC) address assigned by the Orion project. The command and date protocol will comply with the C3I standards. The UPC telemetry and command definitions will be written in Extensible Markup Language (XML). The UPC Date Exchange Message (DEM) will be encapsulated within rate constraint Universal Datagram Protocol (UDP) and delivered via Internet Protocol Version 4 (IPv4) over the Ethernet as showed below.


EthernetIPv4UDPDEM



The UPC requires a digital data link while attached inside Orion via use of a spaceflight umbilical. The Orion Umbilical needs a mate/demate connector for either the fixed or ESS mode when the UPC is deployed.[reword for clarity; UPC is not "deployed"; umbilical is not baselined] The UPC Umbilical placement, dimensions, power, and mass need to be defined as well as the data formats and CCSDS structure for communications. Commands are 2Kbps, Housekeeping is 20Kbps, and Science TBD data rate.

The Orion to UPC Umbilical consists of: Essential Power Non-essential Power Grounds Digital low rate Command Line Digital Housekeeping low rate Telemetry Line Digital High Speed Science and Playback Line

UPC Command

TDRS

White Sands

Complex

GN StationsRF for Orionand/ or I SS

UPC Science & Housekeeping

UPC Digitally MuxedCMD 2KbpsTLM 20Kbps

TBD Science via OrionScience up to 100Mbps via I SS

ISS

Orion

UPC Attachedvia Umbilical

Via Orion or ISS

Orion RFServices

Muxed withDigital UPC

I SS RFServices

Muxed withDigital UPC

TDRS RF Forward & Return Services

below GEO

Orionor I SSMOC

Orionor I SSMOC

RF

Digital/ Hard Line

Figure 5-7

The UPC digital TT&C and high rate telemetry data communications are multiplexed through the Umbilical while attached to Orion or ISS as shown in the above figure. The UPC multiplexed data will be embedded inside the Orion or the ISS digital data stream,




and the UPC telemetry will be transposed into a combined RF signal when communicating to the ground stations or relayed through TDRS to the White Sands complex. The UPC downlink data will be demodulated at the ground station, the ground station will either strip out the UPC digital data or deliver the multiplexed data to the Orion or ISS MOC, and the MOC will separate the UPC data and ship it to the UPC MOC. The UPC command data comes from the UPC MOC, goes to the Orion or ISS MOC and gets multiplexed into their uplink data. Commands are sent digitally to a ground station which takes the combined data and RF modulates it, transmits the signal to Orion or ISS via directly or by use of TDRS, and sends the commands to UPC via the Umbilical. The UPC digital data can also be sent by an astronaut via hard line to the Orion or ISS Umbilical for contingency operations and monitoring purposes with the use of an on-orbit Personal Computer System (PCS). The UPC data rates and integrated paths need to be further developed.

5.3.2.1.1. Electromagnetic Effects [under Avionics Rqmts]

Electromagnetic CompatibilityDefine the appropriate electromagnetic compatibility requirements. For example, end-item-1-toend- item-2 interface shall meet the requirements [to be determined] of systems requirements for electromagnetic compatibility.

Electromagnetic InterferenceDefine the appropriate electromagnetic interference requirements. For example, end-item-1-to-enditem- 2 interface shall meet the requirements [to be determined] of electromagnetic emission and susceptibility requirements for electromagnetic compatibility.

GroundingDefine the appropriate grounding requirements. For example, end-item-1-to-end-item-2 interface shall meet the requirements [to be determined] of grounding requirements.

BondingDefine the appropriate bonding requirements. For example, end-item-1-to-end-item-2 structural/mechanical interface shall meet the requirements [to be determined] of electrical bonding requirements.

Cable and Wire DesignDefine the appropriate cable and wire design requirements. For example, end-item-1-to-end-item-2 cable and wire interface shall meet the requirements [to be determined] of cable/wire design and control requirements for electromagnetic compatibility.

5.3.2.1.2.Acoustic [under Mechanical Rqmts]Define the appropriate acoustics requirements. Define the acoustic noise levels on each side of the interface in accordance with program or project requirements.




5.3.2.1.3. Structural Loads [under Mechanical Rqmts]

The loads induced by UPC on the Orion SM during nominal and off nominaloperations shall not exceed the loads defined in CxP 70136-ANXXX,Constellation Loads Data Book, Future Annex.

UPC shall withstand Orion random vibration environments defined inCxP 70143, Constellation Program Induced Environment Design Specification.

The UPC shall withstand depressurization rates as defined in CxPxxxx

5.3.2.1.4. Vibroacoustics [under Mechanical Rqmts]Define the appropriate vibroacoustics requirements. Define the vibroacoustic

loads that each end item must accommodate.

6. Thermal Interfaces 6.1.1.1.1. ThermalThe temperature requirements while attached to the Carrier are defined for the stowed configuration prior to ejection. The RMSS is thermally isolated to the UPC Common Payload Adapter Fitting (CPAF). No heat exchange across interface and payload has its own independent thermal control while attached to the Carrier.

Power from SM provided to enable survival heaters during stowed configuration to maintain payload’s survival limits. Survival heater power required is about 30 Watts (TBR) plus avionics power 81 Watts (TBR) for the ejectable payload’s propulsion system for tanks, fuel lines and thrusters to maintain temperatures above 10ºC. Conditioning and radiation of thermal loads while stored in SM will be provided to payload. For the fixed configuration, heater power required is about 20 Watts (TBR) plus avionics power 36 Watts (TBR).

6.1.1.1.2. Contamination [TBD]

6.1.1.1.3. Air Temp/FlowUPC would require an air flow temperature of 20ºC and humidity of 40 to 60% from SM during launch ascent. UPC is powered off during this phase.
