AU2021100758A4 - ZENIT-AUSTRALIA space launch vehicle - Google Patents

Abstract

ZENIT-AUSTRALIA is deep modification of two stages ZENIT-2 space launch vehicle, which uses different propulsion for both stages, has new guidance and control system, and is adopted for fully automated launch operations from Cape York, Australia. It employs set of same type newly developed gas generator (open) power cycle engines, including single restartable engine with vacuum nozzle for the second stage, and cluster of seven such non-restasrtable sea level engines for the first stage. All engines are using kerosene and liquid oxygen fuel. ZENIT-AUSTRALIA is controlled by newly developed guidance and control system, is fitted for launches at climate conditions of Cape York, Australia, and can support up to four launches per day from single launch pad due to fully automated check out tests, fueling, countdown, and launch process. 1/1 Figure 1

Description

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Figure 1

ZENIT-AUSTRALIA SPACE LAUNCH VEHICLE BACKGROUND OF THE INVENTION

[0001] The present invention is in the field of expendable medium class space launch vehicles. Launch vehicle (rocket) is complicated extreme machine, which uses reactive power to deliver commercial and other payloads to outer space orbit. The most desired space orbit for commercial applications is geostationary orbit, which is circular orbit in Equatorial plane with 35790km radius. In order to reach this orbit payload has to be injected in geotransitional orbit, which is usually elliptical with 36000km apogee, and 180km perigee. Launches from equatorial launch sites allow to inject heavier and more capable payloads to geostationary orbits. Each type of launch vehicle also requires its own specific design and construction of launch pad; launch vehicle and launch pad are, as a matter of fact, two complimentary parts of the single entity.

[0002] Existing space launch vehicles capable to deliver payload to geotransitional orbit are usually built from 3 or more stages. Third restartable in vacuum stage of a launch vehicle is frequent source of very expensive failures of space missions. These launch vehicles also employ 3 or more different types of engines. Use of multiple types of engines makes production of launch vehicles more expensive, and increases probability of very costly failure. Multi- stage launch vehicle also needs 2 or more drop zones at the Earth surface, where used-up 1 and 2 stages, fairing, and other parts land. Using multiple drop zones leads to adverse impact on the environment, makes launch operations less safe, and makes approval process more complicated. Furthermore, modem operational launch vehicles need from 24 hours to several days preparation at the launch pad before they can lift-off. Long wait period at launch pad exposes launch vehicle to changing weather, action of various adverse environment factors, and makes campaigns which involve frequent launches impossible.

[0003] USA Space-X company had recently developed launch vehicle FALCON-9, which is capable to inject payloads to geotransitional orbit using only two stages, and single type of engine. This launch vehicle however still requires over 24 hours at the launch pad. It also can be launched only from USA soil, i.e. not closer than 280 north to Equator, but still is big commercial success.

[0004] Launch vehicle ZENIT-AUSTRALIA is deep modification of proven ZENIT-2 launch vehicle, which is operational since 1985. ZENIT-2 was developed to operate from Kazakhstan launch site Baikonur, which has extreme continental desert climate conditions. It needs 3rd stage for injection payloads into geotransitional orbit. Nevertheless ZENIT-2 is the launch vehicle, around which Sea Launch project was built. ZENIT-2 employs single powerful 4-chamber RD-171 engine for the 1" stage, and single chamber RD-120 engine for the second stage, neither is restartable, and both use staged combustion power cycle.

[0005] ZENIT-AUSTRALIA launch vehicle employs single type of engines, can be prepared for launch in 6-10 hours, and uses structural design and components of ZENIT-2. It will be launched from Australian launch site at northern tip of Cape York peninsula, which is 12,5 south from Equator i.e. is much more favourable for launches to geotransition orbit. It is tandem architecture 2 stages launch vehicle, which is suitable for operations at tropical climate conditions of Cape York peninsula. It employs new RD-1060 single type gas generator (open) cycle rocket engines for first and second stages. First stage is powered by cluster of seven non-restartable RD-1060 engines, having 981kN sea level thrust each. Second stage is powered by single restartable RD-1060 engine with vacuum nozzle, which delivers 103OkN thrust in vacuum. ZENIT- AUSTRALIA also has streamlined automated launch preparation, which provides cost effective launch operations, unparalleled workplace safety, and fast turnaround of launches. It also needs only single drop zone for 1 stage and fairing, while 2"d stage burns in atmosphere, which makes it mush safer for environment. Thrust vector control for both stages of ZENIT-AUSREALIA is executed by combination of gas turbine exhaust and gimbaled engines. Reaction control for the 2"d stage is provided by gimbaled engine and cold gas thrusters.

[0006] Use of 8 similar engines per launch vehicle allows to establish mass production of engines, and drastically cut overhead production costs, compared to all existing launch vehicles except for Merlin engine of FALCON-9. Any other operational launch vehicle will have essentially higher cost of propulsion that provides similar trust parameters. ZENIT-AUSTRALIA also uses environment friendly fuels (refined kerosene RP-1 and liquid oxygen); using such fuels, combined with employing of single drop zone, places ZENIT- AUSTRALIA among the world's most environment friendly launch vehicles.

[0007] ZENIT-AUSTRALIA (Figure 1) provides delivery of payload having mass over 3700 kg to circular geotransition orbit 6000km diameter, or elliptical orbit with apogee 36000km, and perigee 180km; over 8000 kg to 500 km altitude Sun-Synchronous orbit; payloads of over 13.500 kg to 200km altitude circular orbit. First stage of ZENIT-AUSTRALIA is 33000 millimeters long and has 3900 mm diameter, has 20000kg empty mass, and uses 256000kg of propellant. Second stage of ZENIT-AUSTRALIA is 10400 mm long, also has 3900mm diameter, has 7000kg empty mass, and uses 33000kg of propellant. Launch vehicle fairing of head unit of ZENIT-AUSTRALIA provides payload envelope which has 4600mm internal diameter and useful 7530mm length. Second stage of launch vehicle supports 5 restarts, and uses the fuels same as the first stage.

[0008] ZENIT-AUSTRALIA stages and head module are manufactured by YUZHMASH in Ukraine, and are shipped to Australia for final integration of the launch vehicle and payload in horizontal position at the vehicle integration building of Australian launch site. Integrated launch vehicle is rolled out from vehicle integration building and transported to the launch pad in horizontal position, already installed on launch vehicle erector. All operations after launch vehicle leaves vehicle assembly building are conducted in automated regime. Upon arrival to launch pad launch vehicle is erected to vertical position, undergoes final check out tests, fueled, undergoes pre launch tests, and is launched, still in automated regime. No human hand touches launch vehicle after erection to vertical position under normal conditions.

[0009] Upon launch, longitudinal G-forces applied to payload do not exceed 6G at any time during flight; lateral acceleration of the payload does not exceed 2.35G; acoustic load on the payload does not exceed 135.2 dB; vibration acceleration of the payload does not exceed 40 m/s ; payload shock loads do not exceed 1200G; the temperature inside the fairing does not exceed 930 C.

PRIOR AUSTRALIA PATENTS

[0010] Australian patent search for "launch vehicle" and "rocket" patents identified INTERNATIONAL APPLICATION WO 2014/152778 Al filed 14.03.2014, International Patent Classification: B64G 1/00 (2006.01) B64G 1/40 (2006.01), F41B 6/00 (2006.01), "LAUNCH VEHICLE AND SYSTEM AND METHOD FOR ECONOMICALLY EFFICIENT LAUNCH

THEREOF". The patent is for method of injection of payloads into space, which is alternative to traditional chemicals combustion method, which is employed by ZENIT-AUSTRALIA. The patented principle is applicable to light payloads only; there is no recognizable correlation between ZENIT-AUSTRALIA, and patented method.

[0011]. Australian application 2014239188 "Launch vehicle and system and method for economically efficient launch thereof', which is protecting Intellectual Property for above discussed method in Australia, specifying direction rail as payload injection instrument. Directional rail is not used by ZENIT-AUSTRALIA. The Application refers to Additional/Division application 2017218955.

[0012] Australian patents 2006322650 Hybrid rocket system; 2018903090: Jarmyn Enterprise Space X1 multistage propulsion system, turbofanjet, scramjet, liquid feul rocket in one - are related to different rocket design principles, none of them employed by ZENIT-AUSTRALIA.

[0013] Australian patents: 2004274828: Rocket engine having guide vanes in the nozzle of the engine; 2019100068: The disclosed method of operation is a cycle which creates propulsion. This propulsion is a result of interactions of masses; 2017318721: Additive manufactured combustion engine; 2014206671: Rocket motors and their use; 2008295569: Integral composite rocket motor dome/nozzle structure patents are related to different propulsion systems, but none of them is employed by ZENIT-AUSTRALIA.

[0014] Australian patents: 2018902666: Method for Returning a Re-usable Space Lift Rocket back to Earth using Aerodynamic Propulsion; 2017427814: Rocket launch module and rocket launch vehicle - are related to methods of launching rockets, none of them employed by ZENIT AUSTRALIA.

INTERNATIONAL COMPETITORS

[0015] The only operational 2-stage launch vehicle which operates restartable second stage and is capable to inject payload into geotransitional orbit is USA FALCON-9. FALCON-9 became operational in 2010, while ZENIT's maiden flight took place 25 years earlier, in 1985. FALCON-9 and ZENIT- AUSTRALIA use different rocket engines that deliver different thrust and are ingenuously and independently developed, employ different independently developed guidance and control systems, have different structural design and architecture, and different thrust vectoring principles. ZENIT- AUSTRALIA also employs fully automated check-out, fueling and countdown, which is not a case for FALCON-9, and provides 5 vacuum restarts compared to two restarts by FALCON-9.

[0016] ZENIT-AUSTRALIA does not use any source code and standards owned by third party, does not use any information disclosed by a third party under a confidentiality agreements, does not utilize technology licensed from or to a third party, and does not relate to any pending license negotiations.

Claims (3)

CLAIMS ZENIT-AUSTRALIA launch vehicle

1. Use of single restartable gas generator (open) power cycle engine with vacuum nozzle for the second stage, and cluster of seven such non-restartable engines with sea-level nozzle for the first stage, all using kerosene and liquid oxygen fuel, replacing staged combustion cycle engines of first and second stages of ZENIT-2 launch vehicle.

2. Adaptation of ZENIT-2 launch vehicle for integration and launch at tropical climate conditions of Cape York, Australia.

3. Fully automated erection, check out, fueling, countdown, and launch operation of ZENIT-AUSTRALIA launch vehicle at launch site at Cape York, Australia.