Mechancial Int Overview

Launch Vehicle Mechanical Integration Group
By V.Kishore Nath
GD, LMIG
2nd May, 2013 Presentation at ZeeDP Program 1

Propulsion System
Launch Vehicle
Mechanical Vehicle Systems

Integration
The process of realising the total vehicle with various sub-

systems is known as integration.
The vehicle systems include

Avionics, Pyro, control & stage auxiliary systems for ignition,
separation & destruct systems
Sub-systems such as Thermal Protection Systems, Umbilicals
etc.
Integration of Satellites
Integration of Launch Vehicle for Mission

2nd May, 2013 Presentation at ZeeDP Program
INTEGRATION SEQUENCE
SUBASSEMBLY PREPARATION AT TRIVANDRUM
& TRANSPORTATION TO MAHENDRAGIRI OR
SRIHARIKOTA
LIQUID / CRYO STAGE INTEGRATION AT LMF,

M.GIRI.
SOLID STAGE INTEGRATION AT SHAR.
VEHICLE BUILD-UP AT LAUNCHPAD.
LAUNCH OPERATIONS.
COUNTDOWN & LAUNCH.
3
WORK CENTRES FOR INTEGRATION
ACTIVITIES
Valiamala (Tvm)
LMF (Mahendragiri)
(Sub assembly Preparation for
(For Liquid Stages)
PSLV & GSLV) Core Base Shroud
1/2L, 1/2M, 1/2V, Equipment Bays, * Mech. Pre Assy. including
Heat Shields, PS3 adaptor, PLA etc) fixing Bond Pads on tanks
* Stage Integration
* Pre-Assy. Mech. Int. operations.
* Inspection /Marking using 3DCMM * Engine Harnessing
* Harness Preparation * Electrical Testing
* Avionic Package Assembly * Leak & Functional checks
* Electrical Checks
* Vibration Assy & Vibration test MVIT
PLANNING, CO-ORDINATION,
& EXECUTION OF INTEGRATION and
CHECKOUT OF LAUNCH VEHICLES
Thumba (Tvm) SRIHARIKOTA
Liquid Stage sub assembly
preparation (PS2, GS2 & L40s), * Preparation of vehicle stages
LVM3 , RSR Payload & RLV * Checkout at Stage Level
assemblies preparation * Vehicle build-up at Pad
* Pre-Assy. Mech. Int. operations. * Alignment Checks
* Harness Preparation * Flight Battery Preparation
* Avionic Package Assembly * Vehicle Checkout
* Electrical Checks * Launch Operations
* Vibration Assembly
4
Major mechanical integration tasks
1. Assembly / installation of
o Avionic packages & electrical harness

o Pyro system components
o Pressure monitoring systems
o Thermal Protection systems
o Electrical & cooling Umbilicals
2. Vehicle level operations
o Satellite Assembly
o Pre-launch Cooling
o Rain proofing
o Umbilical connections
o Alignment
5
Avionic packages, flight batteries, pyro elements are mounted

on various hardwares using
- Honey Comb decks
- Housing Concept
- Bulk Head/ End ring Mountings
Functional grouping is done for avionic & pyro systems.
Access for trouble shooting/replacement is critical

requirement
Avionic / Pyro Mounting schemes

HOUSINGS / DECKS IN GSLV BASE SHROUD
HOUSINGS & DECKS

(For packages)

Mechanical Interfaces- Decks
RMSA ETA
PSLV PS1 Pyro Deck PS3 ADAPTOR AVIONIC DECK

Honey Comb Decks

Structural sandwich with
A pair of thin, strong facings to carry the
loads
A thick, light weight core to separate the
facings to carry the loads from one facing to
other and carry the transverse shear loads.
Inserts in the core to integrate the systems
Advantages
• High strength & stiffness with low mass
• Good vibration damping
9
Pressure Monitoring Scheme

O-Ring based pressure pickup system is used to ensure leak tight
joint
Pressure Pickup
Secondary
Igniter
Primary
Igniter
Dome Pressure Pickup

BONDING ON STAGE TANKS / MOTORS

Bond pads required for
o To route interconnecting wire bunches on tanks/CFRP structures
o To mount pyro destruct cords
o To mount sensors on tank interfaces
Most of the pads are welded on steel motor cases at work centre itself. A few
are additionally bonded during stage preparation.
All pads on aluminium propellant tanks of liquid & cryo stages are bonded
instead of welding to avoid localised residual stresses.
The typical bonding procedure involves,

• Surface preparation on pad and tank, by cleaning agents
• Bonding of degreased pads using structural adhesives
• Application of pressure using specially designed fixtures.
Incase of solid motor (PS3 in PSLV) made of reinforced fibre material, the
dilations values are high. Hence the pads are bonded with intermediate rocasin
sheet to absorb dilation.
2nd May, 2013 Vehicle
Presentation at ZeeDPIntegration
Program at Launch Complex 11
Bond pads over

Bond pads over L40 tank SITVC bond pads
Cryo tank
Bonding on tanks

FIXTURE LOADED WITH BOND PADS PAD AFTER BONDING
PS3 BOND PAD SCHEME

Interfaces for Electrical
Launch harness
Vehicle Mechanical Integrationrouting
Group in CUS in GSLV
Interfaces for routing Electrical harness provided on

Tanks (Dome and Shell)
Bridging Plates
Lower Truss

Thermal Protection System (TPS)
To limit the temperature of vehicle hardwares made of
Aluminum materials, thermal protection is given (limit is 120
deg.C).
TPS Materials
Epoxy based thermal paints

Silica cloth
Silica tapes with metallic foil
Ceramic wool, tape.
Thermal paint is applied by mechanized spray station at

HAL & Mahendragiri
15
MULTIPLE SATELLITE INTEGRATION (PSLV-C7)

ISOLATION SYSTEM FOR

LAUNCH VEHICLE SUB ASSEMBLIES
The launch vehicle assemblies are subjected to SINE
and Random vibration and hence the crucial
components like avionics and pyro components are
to be protected by using isolators.
Factors for selecting a proper isolator
System natural frequency, Input dynamic
disturbance (Sine, Random).
Load per isolator (static & dynamic), Space
constraints.
Allowable displacement and response, Fail safe INDIGENOUS ISOLATORS
construction.
Specifications of isolators
Load rating (Kgs)
Natural frequency at its rated load (Hz.)
Amplification at resonance ( usually 5 times)
Type of mounting(usually stem type). ISOLATED DECK

VIBRATION ISOLATOR
ISOLATED HONEY COMB DECK
Vibration Isolation of critical systems in launch

vehicle
Joints:: Fastener Stiffness

Joints
A launch vehicle joint has to with stand external tensile loads, moment
loads, and shear loads, or a combination of these.
Twisting the nut stretches the bolt to

produce the clamping force. This clamping
force is called the pretension or bolt
preload.
This force exists in the connection after the
nut has been properly tightened.
The friction factor determines the exact pre-

load transferred to the joint.
Hence it is experimentally evaluated by using

load washers.

Launch Vehicle Umbilical Systems

Umbilicals provide the link between ground systems and
launch vehicle to service the vehicle till lift off.
Umbilical types
Electrical Pneumatic Cryo Cooling
Umbilicals will be separated at vehicle lift-off

Launch Vehicle Umbilical Systems

Umbilical Connectors
Push Pull Pin Umbilical 61/128 Pin Umbilical

Connector
Indigenisation completed for all the above

Umbilical connectors
Acceptance tests are introduced for

imported DEUTSCHE & SOURIAU Umbilicals 282 Pin Umbilical Connector
used for PSLV/GSLV

Thank You
23

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Launch Vehicle Mechanical Integration Group

2nd May, 2013 Presentation at ZeeDP Program 1

Mechanical Vehicle Systems

The process of realising the total vehicle with various sub-

The vehicle systems include

Integration of Launch Vehicle for Mission

LIQUID / CRYO STAGE INTEGRATION AT LMF,

SOLID STAGE INTEGRATION AT SHAR.

VEHICLE BUILD-UP AT LAUNCHPAD.

COUNTDOWN & LAUNCH.

o Avionic packages & electrical harness

2. Vehicle level operations

Avionic packages, flight batteries, pyro elements are mounted

- Honey Comb decks

- Bulk Head/ End ring Mountings

Functional grouping is done for avionic & pyro systems.

Access for trouble shooting/replacement is critical

Avionic / Pyro Mounting schemes

2nd May, 2013 Presentation at ZeeDP Program

HOUSINGS / DECKS IN GSLV BASE SHROUD

HOUSINGS & DECKS

2nd May, 2013 Presentation at ZeeDP Program

Mechanical Interfaces- Decks

PSLV PS1 Pyro Deck PS3 ADAPTOR AVIONIC DECK

2nd May, 2013 Presentation at ZeeDP Program

Honey Comb Decks

Pressure Monitoring Scheme

Dome Pressure Pickup

BONDING ON STAGE TANKS / MOTORS

The typical bonding procedure involves,

Bond pads over

2nd May, 2013 Presentation at ZeeDP Program 12

FIXTURE LOADED WITH BOND PADS PAD AFTER BONDING

PS3 BOND PAD SCHEME

2nd May, 2013 Presentation at ZeeDP Program

Interfaces for routing Electrical harness provided on

2nd May, 2013 Presentation at ZeeDP Program

Epoxy based thermal paints

Thermal paint is applied by mechanized spray station at

MULTIPLE SATELLITE INTEGRATION (PSLV-C7)

2nd May, 2013 Presentation at ZeeDP Program 16

ISOLATION SYSTEM FOR

2nd May, 2013 Presentation at ZeeDP Program

ISOLATED HONEY COMB DECK

Vibration Isolation of critical systems in launch

Joints:: Fastener Stiffness

Twisting the nut stretches the bolt to

The friction factor determines the exact pre-

Hence it is experimentally evaluated by using

2nd May, 2013 Presentation at ZeeDP Program

Launch Vehicle Umbilical Systems

Electrical Pneumatic Cryo Cooling

Umbilicals will be separated at vehicle lift-off

2nd May, 2013 Presentation at ZeeDP Program

Launch Vehicle Umbilical Systems

2nd May, 2013 Presentation at ZeeDP Program

Push Pull Pin Umbilical 61/128 Pin Umbilical

Indigenisation completed for all the above

Acceptance tests are introduced for

2nd May, 2013 Presentation at ZeeDP Program