Periodic Reporting for period 2 - ENVOL (European Newspace Vertical Orbital Launcher)
Reporting period: 2021-08-01 to 2023-04-30
The ENVOL is a Horizon 2020 project funded by the EU starting February 2020 and ends 3 years later.
ENVOL main objective is to provide Europe its prime commercial, competitive and green launch service, utilizing a true New Space approach to offer low-cost, frequent and flexible access to space to small satellites up to 200 kg by 2026.
9 industrial companies from 7 European countries participated in the project:
- NAMMO Raufoss AS (Coordinator)
- CT Ingenierie
- GTD Sistemas de Información SA
- SpaceTec Partners SPRL
- Evonik Resource Efficency GMBH
- ISISpace – Innovative Solutions in Space BV
- GKN Aerospace Sweden AB
- Airborne Composites BV
- Andøya Space center AS
The main outputs of ENVOL are:
- A detailed definition of an innovative and industrial low-cost European launch system.
- A total of four ambitious launch vehicle demonstrators: Propellant turbo-pump, the tank and structures, the launcher avionics and the payload avionics.
- A business plan.
ENVOL main objective is to provide Europe its prime commercial, competitive and green launch service, utilizing a true New Space approach to offer low-cost, frequent and flexible access to space to small satellites up to 200 kg by 2026.
9 industrial companies from 7 European countries participated in the project:
- NAMMO Raufoss AS (Coordinator)
- CT Ingenierie
- GTD Sistemas de Información SA
- SpaceTec Partners SPRL
- Evonik Resource Efficency GMBH
- ISISpace – Innovative Solutions in Space BV
- GKN Aerospace Sweden AB
- Airborne Composites BV
- Andøya Space center AS
The main outputs of ENVOL are:
- A detailed definition of an innovative and industrial low-cost European launch system.
- A total of four ambitious launch vehicle demonstrators: Propellant turbo-pump, the tank and structures, the launcher avionics and the payload avionics.
- A business plan.
Dissemination
ENVOL provided project updates to reach out to any interested parties, using ENVOL social media channels. Open access publications and result-oriented project progress were promoted throughout ENVOL’s networks.
Commercial Opportunities
A thorough market assessment has been performed. The analysis of the market includes an overview of the global space economy, the global satellite market outlook, space-launch industry and micro-launcher landscape.
Launch System
High Level Requirements for the whole ENVOL system have been developed. A CONcept of OPerationS for ENVOL has been proposed to reflect the HLR into a planned progress of ENVOL during its exploitation phase, with particular focus on simplicity and flexibility.
The development plans of the main sub-systems, their non-recurring and recurring costs have been presented to draw the full cost file of ENVOL and estimate the time needed for its development. A Capella model (CT) for the launch vehicle was extensively used for all interfaces including the ground segment. The complete cost figure of the launch system has been assessed. The development plans of the main sub-systems, their non-recurring costs (NRC) and recurring costs (RC) have been presented.
Several option to reduce the costs and improve the performances have been analysed, with their respective impact on the development plan, NRC, RC and performance.
Launch Vehicle
Three desig loops have been performed, the first with focus on the definition of the overall system architecture.The second loop was devoted to the consolidation of this reference design.
Finally, the last design loop integrated the cost and development time needed to fully develop the launcher. Two different configurations have been identified and designed by the consortium. The first one, which objective is to enter the market as soon as possible, to make ENVOL a reliable competitor in the NewSpace sector, is called the NEO – 7L.
The architecture of the launch vehicle has been defined, and a Model Based System Engineering (MBSE) tool (Capella) has been used. The launch vehicle was modeled at physical level, and the same was done for the future evolutions of the launcher.
Propulsion system design.
A hybrid motor propulsion system has been designed. Performances, dimensions and masses are given for all propulsion systems, including analysis of possible future upgrades.
Structures of the launcher, except the fairing, have been designed and optimized in order to minimize their mass.,General loads rely on trajectory data, aerodynamics of the LV, Center of gravity and masses of the components forming the LV and the geometry of the LV. It allows to size the different structures composing the LV and looping with CAD and LV design allows to reach a final configuration for ENVOL. This activity has been conducted in parallel of the trajectory optimization in order to find the best compromise between aerodynamic loads acting on the LV, and thus heavy structures, and the flight incidence maximizing the performance.
Ground Segment
The work was focused on the interactions and collaboration with partner Andøya Spaceport. A Requirement review between to assess the compatibility between both systems, flight and ground, and the acceptance and conformity of ENVOL launch service operating at Andøya Space Center at the current design point has been performed. The approach was that the interfaces are standard, simple and flexible enough to adapt the LSO infrastructures to hosting multi-launcher campaigns, and secondly focus on the reduction of the initial investment on the launch complex (or Mission control) and hence the reduction of the risks of investing in services interfacing the LSPs while still under design and development.
Avionics.
Two development loops on avionics architecture was performed, including development of a FSW demonstrator focused on the Guidance and Navigation Control (GNC), Flight Manager (FM) and Safety algorithms, and a OBFSW demonstrator for validation of the OBFSW using the processor-in-the-loop approach, pluss development of a missionisation tool and an operator interface.
Two architecture were defined, one innovative and one more conservative approach.
The validation of the FSW and the implementation of the missionisation tool have been performed. The tests respected the HLR and therefore the FSW is validated in a representative environment.
Demonstrators
Structure:
The structural design by CT has been made with manufacturing limitations and possibilities supplied by Airborne. Several iterations of the design have been performed and the best design has been used to start defining the manufacturing process and corresponding tooling. This was then exploited to build one second stage tank, including skirts, in scale 1:1 that was later pressure tested to validate its structural integrity and obtain valuable data for the next development phases.
Turbo Pump:
Conceptual design of the turbopump unit was performed, with attention on performances, costs, market availability and development time. A final design has been selected and a demonstrator has been manufactured and tested with water to verify functionality and capacity.
H2O2 Compatibility:
Compatibility of different materials regarding high tested peroxide (H2O2 > 80%) was investigated. A test procedure haa been developed. Different materials were tested according the defined procedure.
Payload
The Launch vehicle Command module houses redundant interfaces to an Apply Before Flight connector and external EGSE systems as well as the command signals from the LV which will activate the MPDA for use.
The Deployer interface module houses redundant interfaces to at least 4 deployer HDRMs via connectors on its connector plate.
The Launch vehicle telemetry module houses redundant interfaces to the telemetry streams from the rest of the system.
A dedicated payload deployment sequencer was developed. It performed nominally during several tests including functional, thermal and EMC, and was deemed ready for further qualification testing and eventual operational use.
ENVOL provided project updates to reach out to any interested parties, using ENVOL social media channels. Open access publications and result-oriented project progress were promoted throughout ENVOL’s networks.
Commercial Opportunities
A thorough market assessment has been performed. The analysis of the market includes an overview of the global space economy, the global satellite market outlook, space-launch industry and micro-launcher landscape.
Launch System
High Level Requirements for the whole ENVOL system have been developed. A CONcept of OPerationS for ENVOL has been proposed to reflect the HLR into a planned progress of ENVOL during its exploitation phase, with particular focus on simplicity and flexibility.
The development plans of the main sub-systems, their non-recurring and recurring costs have been presented to draw the full cost file of ENVOL and estimate the time needed for its development. A Capella model (CT) for the launch vehicle was extensively used for all interfaces including the ground segment. The complete cost figure of the launch system has been assessed. The development plans of the main sub-systems, their non-recurring costs (NRC) and recurring costs (RC) have been presented.
Several option to reduce the costs and improve the performances have been analysed, with their respective impact on the development plan, NRC, RC and performance.
Launch Vehicle
Three desig loops have been performed, the first with focus on the definition of the overall system architecture.The second loop was devoted to the consolidation of this reference design.
Finally, the last design loop integrated the cost and development time needed to fully develop the launcher. Two different configurations have been identified and designed by the consortium. The first one, which objective is to enter the market as soon as possible, to make ENVOL a reliable competitor in the NewSpace sector, is called the NEO – 7L.
The architecture of the launch vehicle has been defined, and a Model Based System Engineering (MBSE) tool (Capella) has been used. The launch vehicle was modeled at physical level, and the same was done for the future evolutions of the launcher.
Propulsion system design.
A hybrid motor propulsion system has been designed. Performances, dimensions and masses are given for all propulsion systems, including analysis of possible future upgrades.
Structures of the launcher, except the fairing, have been designed and optimized in order to minimize their mass.,General loads rely on trajectory data, aerodynamics of the LV, Center of gravity and masses of the components forming the LV and the geometry of the LV. It allows to size the different structures composing the LV and looping with CAD and LV design allows to reach a final configuration for ENVOL. This activity has been conducted in parallel of the trajectory optimization in order to find the best compromise between aerodynamic loads acting on the LV, and thus heavy structures, and the flight incidence maximizing the performance.
Ground Segment
The work was focused on the interactions and collaboration with partner Andøya Spaceport. A Requirement review between to assess the compatibility between both systems, flight and ground, and the acceptance and conformity of ENVOL launch service operating at Andøya Space Center at the current design point has been performed. The approach was that the interfaces are standard, simple and flexible enough to adapt the LSO infrastructures to hosting multi-launcher campaigns, and secondly focus on the reduction of the initial investment on the launch complex (or Mission control) and hence the reduction of the risks of investing in services interfacing the LSPs while still under design and development.
Avionics.
Two development loops on avionics architecture was performed, including development of a FSW demonstrator focused on the Guidance and Navigation Control (GNC), Flight Manager (FM) and Safety algorithms, and a OBFSW demonstrator for validation of the OBFSW using the processor-in-the-loop approach, pluss development of a missionisation tool and an operator interface.
Two architecture were defined, one innovative and one more conservative approach.
The validation of the FSW and the implementation of the missionisation tool have been performed. The tests respected the HLR and therefore the FSW is validated in a representative environment.
Demonstrators
Structure:
The structural design by CT has been made with manufacturing limitations and possibilities supplied by Airborne. Several iterations of the design have been performed and the best design has been used to start defining the manufacturing process and corresponding tooling. This was then exploited to build one second stage tank, including skirts, in scale 1:1 that was later pressure tested to validate its structural integrity and obtain valuable data for the next development phases.
Turbo Pump:
Conceptual design of the turbopump unit was performed, with attention on performances, costs, market availability and development time. A final design has been selected and a demonstrator has been manufactured and tested with water to verify functionality and capacity.
H2O2 Compatibility:
Compatibility of different materials regarding high tested peroxide (H2O2 > 80%) was investigated. A test procedure haa been developed. Different materials were tested according the defined procedure.
Payload
The Launch vehicle Command module houses redundant interfaces to an Apply Before Flight connector and external EGSE systems as well as the command signals from the LV which will activate the MPDA for use.
The Deployer interface module houses redundant interfaces to at least 4 deployer HDRMs via connectors on its connector plate.
The Launch vehicle telemetry module houses redundant interfaces to the telemetry streams from the rest of the system.
A dedicated payload deployment sequencer was developed. It performed nominally during several tests including functional, thermal and EMC, and was deemed ready for further qualification testing and eventual operational use.
The project completed the PDR2 successfully.
The project succeeded to achieve a full launcher design, and mature the critical technologies with the development and successful testing of the four demonstrators.
ENVOL has proven to have the potential to provide affordable, flexible and green access to space from Europe for small satellites.
The project succeeded to achieve a full launcher design, and mature the critical technologies with the development and successful testing of the four demonstrators.
ENVOL has proven to have the potential to provide affordable, flexible and green access to space from Europe for small satellites.