First Stage Engine Recovery via Segmented Splashdown
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Solution Overview
Problem
The high cost and complexity of recovering and reusing launch vehicle first stage hardware, particularly main engines, due to the need for additional fuel and guidance systems, result in increased expenses despite the potential for savings from reuse.
Innovation Solution
Deploying parachutes and parafoils to decelerate the first stage, severing it into sections, and using controlled explosions to create holes and buoyancy devices for controlled splashdown and recovery, reducing weight and facilitating the reuse of the main engine without damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional fuel and guidance systems are carried to enable controlled recovery of the first stage, then the first stage can be recovered and reused, but the launch cost increases due to the additional weight and systems required
Solution Approach 1:
The first stage is divided into two separable sections: a first section containing the main engine and a portion of the propellant tank, and a second section containing the remaining propellant tank. This segmentation allows the first section to be recovered while the second section is discarded, reducing the complexity of recovering the entire first stage intact.
Solution Approach 2:
The main engine and a portion of the propellant tank are extracted from the first stage as a separate recoverable unit. By taking out only the valuable components (main engine and part of the tank) rather than the entire first stage, the system reduces the complexity and cost of recovery operations.
2Ease of manufacture
If the first stage is severed into two sections to reduce weight and facilitate controlled splashdown, then the recovery process becomes more economical, but the structural integrity of the first stage is compromised
Solution Approach 1:
The first stage is segmented into two sections with a controlled separation point. This segmentation is designed to occur at a predetermined location that balances structural integrity during flight with the ability to separate cleanly for recovery. The first section (containing the main engine) is separated from the second section (containing the remaining propellant tank) at an optimized point that maintains strength where needed.
Solution Approach 2:
The separation mechanism is prepared in advance during manufacturing, with predetermined separation points and methods built into the first stage structure. This preliminary preparation ensures that when separation occurs during flight, it happens at the optimal moment and location to maintain structural integrity while enabling economical recovery.
3Object-affected harmful factors
If parachutes and parafoils are deployed to decelerate the first stage, then the main engine is protected from damage during descent, but the device complexity increases
Solution Approach 1:
The parachute system is integrated with the first section structure, combining the deceleration function with the existing first stage components. By merging the parachute deployment system with the first section rather than adding a completely separate complex system, the protection function is achieved with reduced additional complexity.
Solution Approach 2:
The first section is designed to be self-sufficient for its recovery function, carrying its own parachute and parafoil systems that are deployed automatically upon separation from the second stage. This self-service approach eliminates the need for external recovery systems, reducing overall device complexity while still providing protection during descent.
4Stability of the object's composition
If controlled explosions are used to create holes in the fuselage for water entry, then the first section achieves stable orientation and buoyancy in water, but the structural integrity of the first section is compromised
Solution Approach 1:
Holes are pre-formed in the fuselage structure during manufacturing rather than being created during flight. This preliminary action allows the fuselage to maintain its full structural integrity during the launch and separation phases, while still enabling controlled water entry and stable orientation when the first section enters the water during recovery.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the economical recovery and reuse of launch vehicle main engines by minimizing damage and weight, allowing for efficient tracking and retrieval of the engine after splashdown, thus reducing overall launch costs.
Implementation Method 1
one or more parachutes are deployed to decelerate the decent of the first stage and main engine
Implementation Method 2
a second set of controlled explosions form a series of holes in the fuselage of the first section
Implementation Method 3
the air within the propellant tanks acts as an air spring, allowing for gradual displacement of the water below the vehicle
Data Source
AI summary
A method for preserving and recovering the main engine of the first stage of a multistage launch vehicle involves utilizing a portion of a first stage propellant tank together with a parachute and a deployed buoyancy device to float the engine in a body of water until the engine can be recovered. Controlled explosions remove portions of the propellant tank to permit it to stabilize the position of the engine relative to the water following splash down.