Development of a Light-Weight, Reliable, Booster System for SHELS-Launched Payloads

Small satellite missions are often used to support low-cost space missions demonstrating new technologies. An economical source of low-cost space lift is to fly these satellites as secondary payloads aboard the Space Shuttle. The Shuttle has accommodations for flying these payloads using the Shuttle Hitchhiker Experiment Launch System (SHELS). While the relative costs for a Shuttle launch are at least an order of magnitude below the cost of a dedicated Expendable Launch Vehicle (ELV), final orbit altitude selection is limited to Shuttle mission goals. The Air Force Space Test Program (STP) is responsible for flying the Space Experiments Review Board (SERB) recommended experiments on a level-of-effort basis. Low-cost space lift is crucial to maximizing the number of SERB payloads that STP can support. Unfortunately, the typical Shuttle orbit does not provide a high enough orbit to guarantee the oneyear orbital lifetime required to meet STP mission objectives. A low-cost, autonomous STP Transfer Upper stage, Guided (TUG) that can boost an STP payload from a typical Shuttle orbit to a higher, longer duration orbit would allow STP to take advantage of the low-cost space lift provided by the Shuttle and still meet their mission requirements. The Air Force Research Laboratory Space Vehicles Directorate (AFRL/VS) is pursuing a solution to fulfill STP’s satellite lifting requirements by developing a low-cost, lightweight, reliable, strap-on propulsion module using several Small Business Innovative Research (SBIR) contracts focused on various parts of the TUG system. The Shuttle Expendable Rocket for Payload Augmentation (SHERPA) program will integrate all of these SBIR programs to meet the STP TUG requirement. The TUG system would be composed of several technologies being developed or already developed by AFRL/VS such as separation systems, guidance systems, propulsion modules, and modular bus architecture. The TUG would be re-startable for multiple orbit changes, station keeping, or deorbiting at the completion of a mission. Three versions of the TUG are envisioned. The first is a simple propulsion module that uses the satellite\u27s Attitude Control System (ACS) and Guidance, Navigation, and Control (GN&C) to provide stack guidance. The second is a fully autonomous TUG that lifts the payload to the higher orbit as cargo, separates from the payload, and then accomplishes a collision avoidance maneuver and propellant burn after payload separation. The third configuration is an autonomous TUG with a long duration module that allow experiments to use the TUG\u27s ACS, GN&C, and power systems in the intended final orbit. There are many challenges in the development of this vehicle. The most difficult of these is meeting the man-rating requirements of the Shuttle. All critical systems must have triple redundancy to ensure that the system does not threaten the Shuttle, its crew, or its mission. Another complication is producing a structure that meets the strict mass and volume restrictions of the SHELS system. Integration is als o a challenge, as many contractors and technologies are brought together under this program