Reusable Propulsion Module Segmentation for Launcher Recovery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current launchers have high construction and operating costs due to the lack of reusability in their first stages, which are difficult to recover and require significant modifications for return, leading to increased mass and complexity.
Innovation Solution
A two-stage launcher design where the first stage is divided into a reusable module with propulsion, avionics, and a separate non-reusable tank section, allowing the reusable module to detach and land autonomously, using empennage as lifting surfaces and a subsonic engine for controlled return, reducing the need for additional mass and structural reinforcements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first stage is designed to be completely reusable with wings and reinforcement, then the entire first stage can be recovered, but the average density becomes low and the construction cost increases significantly
Solution Approach 1:
The first stage is divided into two separable parts: a reusable lower module containing the propulsion system and a non-reusable upper part containing the fuel tanks. This segmentation allows the expensive propulsion system to be recovered and reused while the empty tanks are discarded, avoiding the need to recover the entire first stage with its low-density empty tank structure.
Solution Approach 2:
The reusable propulsion module is extracted as a separate entity from the consumable tank section. This extracted module can be recovered, refurbished, and reused for subsequent launches, while the tank section is discarded after use, eliminating the complexity of recovering and refurbishing the entire first stage.
2Reliability
If wings are attached to the tank casing for return flight, then the first stage can return to ground, but additional mass must be propelled and tank size must increase
Solution Approach 1:
The propulsion module is segmented as a separate reusable unit that contains all return flight capabilities (wings, aerodynamic surfaces, propulsion system). This modular approach concentrates the added mass in a reusable section rather than distributing it throughout the entire first stage, improving the overall mass efficiency.
Solution Approach 2:
The reusable propulsion module serves multiple functions: it provides propulsion during ascent, houses the crew or payload, and contains all systems necessary for controlled return and landing. This multi-functionality eliminates the need for separate return flight structures attached to the tanks.
3Reliability
If the first stage is made completely reusable, then recovery is achieved, but the development time and cost increase significantly
Solution Approach 1:
The first stage is segmented into a reusable propulsion module and a disposable tank section. This segmentation allows the expensive propulsion system to be recovered and reused multiple times, amortizing its development and manufacturing cost over many flights, while the simpler tank section is discarded after a single use.
Solution Approach 2:
The disposable tank section is discarded after use, while the expensive propulsion module is recovered, refurbished, and reused. This selective recovery strategy focuses resources on refurbishing only the high-value components that justify the reusability investment.
4Productivity
If the first stage separates from the second stage with empty tanks, then the launcher can operate, but the average density becomes very low making recovery difficult
Solution Approach 1:
The first stage is segmented into a dense reusable propulsion module and a low-density disposable tank section. After separation from the second stage, only the dense propulsion module needs to be recovered, while the empty tanks are discarded. This segmentation transforms the recovery problem from recovering a low-density entire first stage to recovering a compact high-density module.
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
This design significantly reduces manufacturing and operational costs by enabling the reuse of high-value components, improving the density and stability of the reusable module, and simplifying the recovery process, while maintaining launcher performance.
Implementation Method 1
braking parachute
Implementation Method 2
propulsive charge
Implementation Method 3
airfoils for subsonic flight
Data Source
Figure 1~4
Figure 5~7
Figure 8A~8B
AI summary
The invention relates to a propulsion module for launching a vehicle into space comprising a reusable module (14), as well as an expendable portion (16) rigidly connected to the reusable module (16) during the launch, said reusable module (14) comprising a propulsion system (8) for launching the vehicle, said reusable module (14) and said expendable portion (16) being intended to separate when the propulsion module reaches a given altitude, the reusable module (14) being suitable for landing in a controlled fashion following a conventional flight, for example for a return to the launch site.