Blow Dryers And Metal Shears: Hacks Of Early Falcon 9 Flights

June 13, 2020 by Roger Cheng 10 Comments

Orbiting over our heads right now are two human beings who flew to the International Space Station in a SpaceX Crew Dragon vehicle on top of a Falcon 9. The majority of coverage focused on the years since human spaceflight last launched from Florida, but [Eric Berger] at Ars Technica reminds us it also makes for a grand ten-year celebration of the SpaceX workhorse rocket by sharing some stories from its early days.

Falcon 9 is a huge presence in the global space launch industry today, but ten years ago the future of a young aerospace company was far from certain. The recent uneventful launch is the result of many lessons learned in those ad-hoc days. Some early Falcon 9 flights were successful because the team decided some very unconventional hacks were worth the risk that paid off. A bit of water intrusion? Dry it out with a blow dryer and seal it back up. Small tear in a rocket nozzle? Send in someone to trim a few inches with shears (while the rocket was standing vertical on the launchpad).

Industry veterans appalled at “a cowboy attitude” pounced on every SpaceX failure with “I told you so.” But the disregard for convention is intentional, documented in many places like this old Wired piece from 2012. Existing enshrined aerospace conventions meant the “how” was preserved but the “why” was reduced to “we’ve always done it this way” rarely re-evaluated in light of advancements. Plus the risk-averse industry preferred staying with flight-proven designs, setting up a Catch-22 blocking innovation. SpaceX decided to go a different way, rapidly evolving the Falcon 9 and launching at a high cadence. Learning from all the failures along the way gave them their own set of “why” to back up their “how” growing far beyond blow dryers and metal shears. We’re happy to see the fail-learn-improve cycle at the heart of so many hacker projects have proven effective to send two astronauts to the space station and likely beyond.

[Photo: SpaceX Crew Demo-2 on the launch pad]

Displaying HTML Interfaces And Managing Network Nodes… In Space!

June 8, 2020 by Roger Cheng 44 Comments

The touchscreen interface aboard SpaceX Crew Dragon is just one of its many differences from past space vehicles, but those big screens make an outsized visual impact. Gone are panels filled with indicator needles in gauges, or endless rows of toggle switches. It looked much like web interaction on everyday tablets for good reason: what we see is HTML and JavaScript rendered by the same software core underlying Google’s Chrome browser. This and many other details were covered in a Reddit Ask Me Anything with members of the SpaceX software team.

Various outlets have mentioned Chromium in this context, but without answering the obvious follow-up question: how deep does Chromium go? In this AMA we learn it does not go very deep at all. Chromium is only the UI rendering engine, their fault tolerant flight software interaction is elsewhere. Components such as Chromium are isolated to help keep system behavior predictable, so a frozen tab won’t crash the capsule. Somewhat surprisingly they don’t use a specialized real-time operating system, but instead a lightly customized Linux built with PREEMPT_RT patches for better real-time behavior.

In addition to Falcon rocket and Dragon capsule, this AMA also covered software work for Starlink which offered interesting contrasts in design tradeoffs. Because there are so many satellites (and even more being launched) loss of individual spacecraft is not a mission failure. This gives them elbow room for rapid iteration, treating the constellation more like racks of servers in a datacenter instead of typical satellite operations. Where the Crew Dragon code has been frozen for several months, Starlink code is updated rapidly. Quickly enough that by the time newly launched Starlink satellites reach orbit, their code has usually fallen behind the rest of the constellation.

Finally there are a few scattered answers outside of space bound code. Their ground support displays (visible in Hawthorne mission control room) are built with LabVIEW. They also confirmed that contrary to some claims, the SpaceX ISS docking simulator isn’t actually running the same code as Crew Dragon. Ah well.

Anyone interested in what it takes to write software for space would enjoy reading through these and other details in the AMA. And since it had a convenient side effect of serving as a recruiting event, there are plenty of invitations to apply if anyone has ambitions to join the team. We certainly can’t deny the attraction of helping to write the next chapter in human spaceflight.

[Photo credit: SpaceX]

NASA’s Long-Delayed Return To Human Spaceflight

June 1, 2020 by Tom Nardi 55 Comments

With the launch of the SpaceX Demo-2 mission, the United States has achieved something it hasn’t done in nearly a decade: put a human into low Earth orbit with a domestic booster and vehicle. It was a lapse in capability that stretched on far longer than anyone inside or outside of NASA could have imagined. Through a series of delays and program cancellations, the same agency that put boot prints on the Moon and built the iconic Space Shuttle had been forced to rely on Russia to carry its astronauts into space since 2011.

NASA would still be waiting to launch its own astronauts had they relied on America’s traditional aerospace giants to get the job done. The inaugural flight of the Boeing CST-100 “Starliner” to the International Space Station in December was an embarrassing failure that came perilously close to losing the unmanned capsule. A later investigation found that sloppy software development and inconsistent testing had caused at least two major failures during the mission, which ultimately had to be cut short as the vehicle couldn’t even reach the altitude of the ISS, to say nothing of making a docking attempt. NASA and Boeing have since agreed to attempt another test of the CST-100 sometime before the end of the year, though a delay into 2021 seems almost inevitable due to the global pandemic.

But America’s slow return to human spaceflight can’t be blamed on the CST-100, or even Boeing, for that matter. Since the retirement of the Space Shuttle, NASA has been hindered by politics and indecisiveness. With a constantly evolving mandate from the White House, the agency’s human spaceflight program has struggled to make significant progress towards any one goal.

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Spacing Out: All The Orbital News You’re Missing

May 30, 2020 by Jenny List 19 Comments

We keep finding more great space stories than we can cover, so here’s a speed-run through the broader picture of the moment as it applies to space flight.

The big news this week was the first launch of a manned SpaceX Crew Dragon capsule to the ISS. I was excited because the pass en route to the space station was scheduled to be visible from the UK at dusk, and on Wednesday evening I perched atop a nearby hill staring intently at the horizon. Except it had been cancelled due to bad weather. The next launch window is planned for today and you can watch it live.

Meanwhile, fashion is the other piece of this manned-launch’s appeal. Their sharply-designed spacesuits have attracted a lot of attention, moving on from the bulky functional Michelin Man aesthetic of previous NASA and Roscosmos garments for a positively futuristic look that wouldn’t be out of place in Star Trek. Never mind that the two astronauts are more seasoned space dog than catwalk model, they still look pretty cool to us. Against the backdrop of a political upheaval at the top of NASA, this first crewed orbital mission from American soil since the retirement of the Shuttle has assumed an importance much greater than might be expected from a run-of-the-mill spaceflight.

While we’re on the subject of the ISS, it’s worth noting that we’re approaching twenty years since the first crew took up residence there, and it has been continuously crewed ever since as an off-planet outpost. This is an astounding achievement for all the engineers, scientists, and crews involved, and though space launches perhaps don’t have the magic they had five decades ago it’s still an awe-inspiring sight to see a man-made object big enough to discern its shape pass over in the night sky. We understand that current plans are to retain the station until at least 2030, so it’s a sight that should remain with us for a while longer.

Closer to Earth are a couple of tests for relative newcomers to the skies. When Richard Branson’s Virgin group isn’t trying to boot millionaires off the planet through its Virgin Galactic operation, it’s aiming to cheaply fling small satellites into orbit from a rocket-toting airborne Boeing 747 with its Virgin Orbit subsidiary. Their first test launch sadly didn’t make it to space, once the rocket had flawlessly launched from the airliner it suffered a fault and the mission had to be aborted. Getting into space is hard.

The second test was never intended to make it into space, but is no less noteworthy. The British company Skyrora have performed a successful ground test of their Skylark L rocket, aiming for a first launch next year and for offering low-earth orbit services by 2023. This is significant because it will be the first British launch since the ill-fated Black Arrow launch in 1971, and with their Scottish launch site the first ever from British soil. If you’ve seen Skyrora mentioned here before, it is because they were behind the retrieval of the Black Arrow wreckage from the Aussie outback that we mentioned when we wrote about that programme.

Looking forward to the coming week, especially today’s rescheduled SpaceX launch. This time however, I’ll check the weather conditions before climbing any hills.

Docking With ISS Isn’t As Easy As You Might Think

May 15, 2020 by Al Williams 48 Comments

Complexity is a funny thing. In prehistoric times, a caveman might float across a lake on a log. That’s simple. But as you add a rudder, a sail, or even a motor, it gets more and more complex. But if you add enough complexity — a GPS and an autopilot, for example, it becomes simple again. The SpaceX Dragon capsule actually docks itself to the ISS. However, the crew on the station can take over manually if they need to. What would that be like? Try the simulation and find out. If you don’t make it on the first, try, [Scott Manley’s] video below might help you out.

This isn’t a flashy Star Wars-style simulator. Think more 2001. Movement is slow and it is easy to get out of control. The user interface is decidedly modern compared to the old Apollo era

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SpaceX Offers NASA A Custom Moon Freighter

April 15, 2020 by Tom Nardi 58 Comments

Under the current Administration, NASA has been tasked with returning American astronauts to the Moon as quickly as possible. The Artemis program would launch a crewed mission to our nearest celestial neighbor as soon as 2024, and establish a system for sustainable exploration and habitation by 2028. It’s an extremely aggressive timeline, to put it mildly.

To have any chance of meeting these goals, NASA will have to enlist the help of not only its international partners, but private industry. There simply isn’t enough time for the agency to design, build, and test all of the hardware that will eventually be required for any sort of sustained presence on or around the Moon. By awarding a series of contracts, NASA plans to offload some of the logistical components of the Artemis program to qualified companies and agencies.

For anyone who’s been following the New Space race these last few years, it should come as no surprise to hear that SpaceX has already been awarded one of these lucrative logistics contracts. They’ve been selected as the first commercial provider for cargo deliveries to Gateway, a small space station that NASA intendeds to operate in lunar orbit. Considering SpaceX already has a contract to resupply the International Space Station, they were the ideal candidate to offer similar services for a future lunar outpost.

But that certainly doesn’t mean it will be easy. The so-called “Gateway Logistics Services” contract stipulates that providers must be able to deliver at least 3,400 kilograms (7,500 pounds) of pressurized cargo and 1,000 kilograms (2,200 pounds) of unpressurized cargo to lunar orbit. That’s beyond the capabilities of SpaceX’s Dragon spacecraft, which was only designed to service low Earth orbit.

To complete this new mission, the company is proposing a new vehicle they’re calling the Dragon XL that would ride to orbit on the Falcon Heavy booster. But even for this New Space darling, there’s not a lot of time to design, test, and build a brand-new spacecraft. To get the Dragon XL flying as quickly as possible, SpaceX is going to need to strip the craft down to the bare minimum.

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Phantom Express: The Spaceplane That Never Was

March 27, 2020 by Tom Nardi 12 Comments

Even for those of us who follow space news closely, there’s a lot to keep track of these days. Private companies are competing to develop new human-rated spacecraft and assembling satellite mega-constellations, while NASA is working towards a return the Moon and the first flight of the SLS. Between new announcements, updates to existing missions, and literal rocket launches, things are happening on a nearly daily basis. It’s fair to say we haven’t seen this level of activity since the Space Race of the 1960s.

With so much going on, it’s no surprise that not many people have heard of the XS-1 Phantom Express. A project by the United States Defense Advanced Research Projects Agency (DARPA), the XS-1 was designed to be a reusable launch system that could put small payloads into orbit on short notice. Once its mission was complete, the vehicle was to return to the launch site and be ready for re-flight in as a little as 24 hours.

Alternately referred to as the “DARPA Experimental Spaceplane”, the vehicle was envisioned as being roughly the size of a business jet and capable of carrying a payload of up to 2,300 kilograms (5,000 pounds). It would take off vertically under rocket power and then glide back to Earth at the end of the mission to make a conventional runway landing. At $5 million per flight, its operating costs would be comparable with even the most aggressively priced commercial launch providers; but with the added bonus of not having to involve a third party in military and reconnaissance missions which would almost certainly be classified in nature.

Or at least, that was the idea. Flight tests were originally scheduled to begin this year, but earlier this year prime contractor Boeing abruptly dropped out of the program. Despite six years in development and over $140 million in funding awarded by DARPA, it’s now all but certain that the XS-1 Phantom Express will never get off the ground. Which is a shame, as even in a market full of innovative launch vehicles, this unique spacecraft offered some compelling advantages.

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