Tag: competition

Proton failure investigation finds quality control the root problem

8:32 am

In the heat of competition: The Russian investigation into the most recent Proton rocket launch failure has now found that the cause of the turbo pump failure was because of significant management failures.

The investigation into the MexSat-1 failure established that a fast spinning shaft inside a turbine of the RD-0212 engine propelling the third stage can break easily due to excessive vibrations. (The turbine is designed to pump propellant into four thrusters which steer the rocket in flight.) Yet, despite the problem lingering in the engine’s design for decades, the fact that two of these three accidents had happened in the past 15 months was itself is not an accident!

In an interview with the Russian business web site BFM.ru, the head of Roskosmos Igor Komarov disclosed that due to recent easing of requirements for the quality of metal that had gone into the production of the shaft, the turbine became more vulnerable to vibrations. Additional fascinating details on the same issue had surfaced on the online forum of the Novosti Kosmonavtiki magazine.

As it turned out, dangerously low requirements for the turbine shaft were set in the design documentation during the development of the rocket. However the issue was identified early during testing and the production team self-imposed extra margins for the affected components to remedy the problem. However in 2013, the new management began questioning why so much manufactured parts had been disqualified during production, even when they had met lowest requirements set in the design documentation. By that time, the new generation of workers and mid-level production managers no longer saw a reason to fight for more stringent requirements, which were actually making their own work more difficult. As a result, the hardware which was barely making through the quality control was certified for the installation on the engine, thus giving the old design flaw more chances to surface. [emphasis mine]

The description above reminds me strongly of the circumstances that took place prior to the Challenger failure in 1986: Engineers trying to fix a problem that managers don’t want to see.

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More problems at Virgin Galactic?

10:02 am

The story outlines what appear to significant problems at Virgin Galactic:

  • Some sources say the company has shelved LauncherOne in favor of a bigger launcher that would be deployed from the bottom of a 747, not WhiteKnightTwo.
  • The company however says LauncherOne is still under development.
  • The company admits that they recently had a LauncherOne test rocket engine explode during testing.

It appears that they have discovered that LauncherOne is not cost effective for meeting their contract with OneWeb to launch 39 satellites. It would only be able put up one satellite at a time. A more powerful launcher however would be too heavy for WhiteKnightTwo.

Thus, after 10 years of development, nothing they have built to date is useful for a profitable operation, and they apparently have to start over.

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Russians confirm their commitment to ISS through 2024

9:36 am

Even as a new crew arrived at ISS, the head of Roscosmos confirmed that the Russians are now committed to sticking with ISS through 2024, as requested by the U.S.

I’ll make a prediction: The station’s life will be extended beyond 2024, but not necessarily under the control of its present international partnership. If the governments involved consider backing out at that time, there will be private companies then capable of taking it over, and will demand that the U.S. transfer ownership to them. This will in turn act to pressure the governments to continue the station’s operation.

Either way, ISS will continue.

Meanwhile, quality control issues continue to pop up with the Russians. One of the solar panels on the Soyuz capsule that delivered crew to ISS yesterday had failed to open when commanded, then decided to pop open unannounced during the docking. They had enough power to get to the station with only one panel, and the panel opening at the wrong time fortunately did not cause any problems, but for the panel to open as it did is without doubt worrisome.

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SpaceX pinpoints likely cause of Falcon 9 failure

4:31 pm

The investigation into the failure of the Falcon 9 launch June 28 now thinks the cause was a failed strut in the upper stage.

The struts are 2 feet long and about an inch thick at its thickest. SpaceX does not make the struts, a supplier does. From now on, each one will be individually checked, Musk said, and the design and material may be altered for added strength. The struts are designed to handle 10,000 pounds of force at liftoff; at the time of the accident, they would have been seeing only 2,000 pounds of force. A failure at such a low threshold is “pretty crazy,” Musk said. The strut most likely failed at its attachment point, he added.

Another change: Beginning with its next launch, each Dragon cargo carrier will be equipped with software for deploying its parachutes. The Dragon destroyed last month, along with an estimated $110 million worth of NASA equipment and supplies, would have survived if the parachutes normally used for descent at mission’s end could have been activated, Musk said.

The investigation is still not finalized, but is likely close to completion.

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Internet tycoon commits $100 million to alien life search

9:16 am

Russian internet entrepreneur Yuri Milner has given SETI $100 million for a ten year project to accelerate their effort to search for evidence of extraterrestrial life.

Understanding why SETI needs private funding is important:

SETI has been going on since 1960, when radio telescopes became sensitive enough to detect signals from another planet if it was broadcasting signals similar to those which our civilization does. Researchers developed devices that could monitor millions of frequencies at once for any signal that looked at all different from that produced by astronomical objects or the natural background. At first funded by universities and NASA, public funding for SETI was axed by Congress in the early 1990s. Since then, the nonprofit SETI League has received funding of a few million dollars a year from private donors.

Congress correctly cut the funds because it isn’t really the business of the federal government to search for alien life. Some taxpayers really don’t want their money used for that purpose, and they should have the right to say no. Instead, Congress essentially told SETI to do it right: Get private funding from people who want the research done. The work will be done more efficiently for less, and no one will be required to contribute who doesn’t want to.

Milner’s contribution now is the biggest donation yet, and suggests that interest in this research is building culturally.

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Russia considers building heavy-lift rocket like SLS

10:05 am

The competition heats up: Sources in Roscosmos, Russia’s government agency in charge of their entire aerospace industry, today revealed that the agency is considering building a heavy-lift rocket, as powerful as NASA’s SLS rocket but more similar to Energia, the heavy-lift rocket built by the Soviet Union in the 1980s.

The cost would be $12.2 billion, or 1 trillion rubles, and would take 7-8 years to complete. If approved, the work would also not begin until after 2025 so that the development of Angara’s full family of rockets is completed first.

Meanwhile, a GAO audit today noted that NASA has little margin for completing SLS on time and on budget.

Big, inefficient, and costly rockets: This is what governments do. Their goal? To provide jobs and pork. Even if the rocket never flies it matters not, as long as that pork keeps flowing.

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India engine test a success

9:55 am

The competition heats up: India has successfully completed a full duration engine test of its most powerful home-built rocket engine.

The Indian Space Research Organisation (ISRO) successfully conducted the much-awaited ‘full endurance test’ of the Geosynchronous Satellite Launch Vehicle Mk III’s indigenous cryogenic CE-20 engine at ISRO Propulsion Complex (IPRC) in Mahendragiri in the district on Thursday. The CE-20 was ignited and tested for 800 seconds from 5 p.m. to study the performance of the engine though the actual required duration was only 635 seconds.

This success puts them ever closer to creating their own rocket comparable to the Falcon 9 and capable of competing for commercial business in the international launch market.

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