The Super Stack 1 assembly is now complete with the mating (stacking) of the forward assembly to the fifth segment simulator. Stack one is made up of eight individual pieces: interstages 1 and 2, the frustum, the forward skirt extension, the forward skirt and the aft, center and forward segments of the fifth segment simulator. It also includes two internal elements, the roll control system and the first stage avionics module.
All five super stack assemblies are now complete in High Bay 4 of the VAB and are ready for stacking on the mobile launcher platform in High Bay 3 later this month.
Just so you know, the reason the rocket is separated into these super stacks has to do with the height and weight of each piece for crane loads during lifting operations.
Super Stack 2: Upper Stage Simulator “Tuna Cans” segment 1
Super Stack 3: Upper Stage Simulator “Tuna Cans” segments 2, 3, 4, 5
Super Stack 4: Upper Stage Simulator “Tuna Cans” segments, 6, 7
Super Stack 5: Spacecraft Adapter, Service Module, Crew Module and Launch Abort System
Stacking is set to begin for the Ares I-X vehicle on Wednesday, July 8 in the Vehicle Assembly Building at Kennedy Space Center. It’s been a long time since the workers in the VAB have seen a new vehicle. In fact, it’s been 25 years since a new vehicle was stacked.
Following nearly three years of work by thousands of dedicated team members, the Ares I-X vehicle is ready for stacking on the Mobile Launch Platform, or MLP, in the Vehicle Assembly Building at Kennedy Space Center.
Over the last week, the management team has met for reviews. Today, a “go” was given for the stacking operations. All of the modification work has been completed in VAB High Bay 3, as well as the Mobile Launch Platform, in preparation for the new Ares I-X vehicle.
Tomorrow, the Ares I-X aft assembly, composed of the aft skirt and aft motor segment, will be rolled from the Rotation Processing and Surge Facility to the VAB and lifted by overhead crane and placed on the MLP. (Be sure to check out the KSC gallery for photo updates.)
Over the next month, the stacking operations will continue with the additional motor segments, simulated upper stage segments and the vehicle will be completed when the simulated crew module and launch abort system is added to the top. (There will be a time-lapse camera. NASA will be posting video and images.)
We will keep you posted on this blog, on our Facebook page and Twitter.
Let the stacking begin!
With 300 employees looking on, the Ares I-X aft skirt rolled out of the Assembly Refurbishment Facility. Senior management including Kennedy Center Director Bob Cabana, Mission Manager Bob Ess, ATK Program Manager Joe Oliva and United Space Alliance Associate Program Manager Roger Elliot spoke at the “pep rally” type event.
The aft skirt is on its way to the Rotation Processing and Surge Facility where it will be attached to the aft motor segment later this week, forming the aft assembly. Although this was an aft skirt for the shuttle program, the team made many modifications for this new vehicle. Some modifications include adding deceleration and tumble motors, avionics and a controller for the auxiliary power unit.
Once the aft assembly is complete, it will be moved to the Vehicle Assembly Building to begin stacking operations in late June.
Today, Ares I-X passed another significant milestone when engineers and technicians successfully completed a hot fire test of the hardware at the Aft Skirt Test Facility at Kennedy Space Center.
The hot fire test is actually a series of tests performed on the Aft Skirt –primarily the Thrust Vector Control (TVC) System. Before the test, the fuel systems are checked for leaks and filled with hydrazine (rocket fuel). The hot fire is a two-minute run of the Auxiliary Power Units (APU) using the hydrazine just as it would on launch day. The electro hydraulic servo-actuators, which control the direction the nozzle is pointing, are commanded to move to various positions to make sure they respond properly to commands. Additionally, the power units are run at 100%, 110% and 112% of capacity to assure that all redundancy modes are working properly.
When the test has been successfully completed the hydraulic systems are left as they are and the hydrazine is taken out. The system will stay in that condition until the Ares I-X vehicle is at the launch pad where the system will be refueled with hydrazine in preparation for launch.
With this milestone complete, the aft skirt will be transferred to the Rotation Processing and Surge Facility next month and attached to the aft motor segment. When attached, these two pieces of hardware make up the aft assembly and will be the first hardware to be stacked on the Mobile Launcher Platform in the Vehicle Assembly Building when that process begins in June.