08-20010 NBOC MLV Documentation and Reports.pdf

08 20010 DOC 01

Mobile Launch Vehicle Chassis System Requirements Matrix

08-20010-DOC-01

03/21/2025

Revision C

Revision Description Date TECH OPS Signature

SAFETY /

QUALITY

Signature

CM Release Signature

- Original Release (Presented at Delta SRR) 6/15/2023

A

The following updates have been made:

- All OSHA references have been updated to match the provided OSHA requirements listed in the requirements documents provided by BPO.

- Updated 3.8.1.1.2 to reflect the increase in Loading from 8000 lbs. to 16000 lbs

- Updated 3.6.4.3.1 to reflect that the requirement is stating "IF" the team decides to go the route of interfacing with the Loader auxiliary hydraulics.

- Added Derived Requirement D.4

- Added Derived Requirement D.5

- Added Derived Requirement D.6

- Added Derived Requirement D.7

8/21/2023

B

Per CR 2593:

- Section 3.8.3.6: transferred responsibility of David Clark Headset to CSBF

- Changed wording in section 3.8.5.6 from "handrails" to "guardrails" to match OSHA definition

2/17/2025

C Per CR 2832:

Updated 29 CFR 1910.140 to 29 CFR 1910 in section 3.8.5.6 3/21/2025

Requirement # Requirement Process/Approach Verification Compliance

3.1.1 The MLV shall accommodate and interface with, the Caterpillar 966M Wheel Loader as the primary power plant.

(PD) has reviewed how the Hercules Launcher interfaces with the loader and will emulate this design. The MLV will attach to the factory forward axle mounting interface, as well as the factory fusion quick coupler (bucket interface). An interface control document (ICD) will be generated from existing 966M assets in Palestine, to ensure the MLV interface will properly mate with the loader.

Design

3.1.2 PD shall satisfy the unique needs for this vehicle through the design of the MLV Chassis Section.

PD will use the requirements itemized, henceforth, to design and document the MLV, such that it satisfies the Balloon Program Office’s (BPO) requirements. The general approach in PD meeting these requirements is outlined below.

- Interview CSBF and BPO stakeholders to ensure that the intent of each requirement is met

- Review the general envelopes of various payload that have been and will be launched.

- Travel to inspect and document "Big Bill" Mobile Launch Vehicle (MLV)

- Review and evaluate existing MLV designs for guidance in meeting the requirements

- Conduct appropriate analyses leveraging heritage PD tools and techniques which have been honed designing fixed and mobile launch platforms for NASA, Navy and Army programs

- Evaluate designs and analyses using government and industry standards to ensure the performance, strength, lifespan, and safety of the ground support system PD will use the guidelines laid out in the NASA Systems Engineering Handbook (SP-2007-6105, section 6.2) to track and manage requirement compliance across the entire requirements matrix as design goals are achieved.

Design

3.2.1.1

The Mobile Launch Vehicle Chassis Section shall be designed in such a way that it does not allow the vehicle to tip over or otherwise allow the vehicle to be damaged if it shall experience the dynamic loads and speeds described in requirements 3.8.

PD will use the dynamic loads and speeds called out in the requirements document (820-REQ-13 MLV Chassis Req 02.24.23_signed.pdf) in sections 3.8.2.1.2 and 3.8.2.2 located on pages 18 – 20 as the basis for the design and tip over analysis.

Analysis

3.2.1.2 It shall impart a maximum ground pressure of 80 psi to accommodate all launch locations.

PD will use the provided specifications of the 966M Wheel Loader and evaluate the ground contact pressure based on:

- Tire pressure

- Tread pattern

- Gross vehicle weight (fuel, fluids, personnel, payload, etc.)

- Vehicle weight distribution/ CG

- Dynamic loading cases

- Surface conditions

Analysis

3.2.1.3 The weight and dimensions for the Mobile Launch Vehicle Chassis Section shall be limited to allow loading and shipment via sea vessel and/or traditional highway transportation (special permits allowed)

- PD will design the overall MLV chassis section such that it can be loaded and shipped via sea vessel and/or traditional high transportation which can include the need for special permits.

- PD will work to collect and understand the maximum dimensions allowed to ship the vehicle via highway transportation and sea vessel.x The following weights and dimensions will be used to guide the design:

DOT Regulations:

- Maximum allowable over the road trailer length (US - 80 ft, New Zealand - 78.7 ft, Australia - 66 ft, Canada - 80 ft, Sweden - 78.7 ft)

- Maximum payload weight without permits (US - 80,000 lbs, New Zealand - 92,500 lbs, Australia - 93,700 lbs, Canada - 102,000 lbs, Sweden - 113,000 lbs) ABS Standards:

- Custom flat racks for cargo shipment

- Maximum allowable weight of shipping cube

Analysis

3.1 GENERAL

3.2.1 Dimensions/Weight

3.2 SPECIFIC REQUIREMENTS

3.2.1.4 The Mobile Launch Vehicle Chassis Section shall not be wider than 25 feet wide in its launch configuration.

PD will design the vehicle such that the chassis is not wider than 25 feet (300 inches) at its widest location while in the launch configuration. Design

3.2.1.5 The Launch Boom shall be 4 feet wide and support a person weighing up to 350 lbs. walking on it. Flooring shall be see-through (current MLV uses expanded metal) and have compliant access such as steps with handrail.

- PD will design the boom such that it between 4 feet (48 inches) and 4 feet 6 inches (54 inches) at its widest location in accordance with requirement 3.8.5.1.

- PD will design and analyze the boom such that it can support a 350 lbs. person walking on it from end to end.

- PD will design and specify the flooring of the boom system such that it is see-through.

- PD will design the boom such that it has an OSHA compliant access point.

Design and Analysis

3.2.1.6 All weights for major components shall be labeled accordingly and shall have appropriate structural lifting points and clearly marked Centers of Mass.

- PD will use flag notes on engineering drawings to mark appropriate lifting points for major components (Defined as components that require crane or forklift equipment to remove).

- PD will label and mark all weights, centers of gravity (CG), and lifting points for major components.

Design

3.2.1.7 Any large or major components that may need to be removed for assembly or disassembly shall contain appropriate lift points or fork pockets as needed.

PD will design, analyze, and mark appropriate lifting points for major components (Defined as components that require crane or forklift equipment to remove). See Requirement 3.2.1.6 for document marking approach.

Design and Analysis

3.2.2.1 The Mobile Launch Vehicle Chassis shall maintain a minimal ground clearance of 18 inches from the ground while carrying the maximum suspended load.

PD will design the chassis such that the minimum ground clearance is 18 inches while carrying the maximum suspended load (8,000 pounds), to account for tire deflection and terrain (approach/departure angles, break-over, etc.)

Design and Analysis

3.2.2.2 The Mobile Launch Vehicle Chassis Boom shall reach a height of at least 40 feet high but no more than 41 ft

PD and CSBF/BPO will define the measurement criteria to satisfy this requirement, and PD will design the boom such that it will reach 40.0 feet tall + 1.0 feet / - 0.0 feet (480 in. + 12 in. / - 0 in) with a combination of boom geometry and industrial equipment design (limit switches, proximity sensors, etc.) per requirement 3.8.5.2.

Design

3.2.2.3 The projected Boom Height distance from the front end of the Mobile Launch Vehicle shall be no less than 12 feet.

PD will design the boom such that it will be no less than 12 feet from the front end of the MLV when fully elevated. (Reference Figure 2 on page 11 of 820-REQ-13 MLV Chassis Req 02.24.23_signed.pdf) per requirement 3.8.5.3.

Design

3.2.3 The Mobile Launch Vehicle Chassis shall have a life cycle of NO less than 30 years provided a reasonable maintenance plan is followed.

PD will use fatigue failure and cycle analyses to identify critical path failure modes and provide design or maintenance solutions to validate the MLV chassis’ ability to function properly for 30 years.PD will also provide inspection points within the standard maintenance plan to assess the MLV for indications of fatigue failure.

Analysis

3.2.4.1 The contractor shall provide evidence of experience and/or background which demonstrates capability for accomplishing work of similar magnitude and complexity.

PD will provide the PD Statement of Capabilities document that provides evidence of PD’s experience in design for dynamic vehicle structures and launch platforms. Past Performance

3.2.4.2

The contractor shall provide a description of the Contractor's capabilities and expertise including but not limited to years of experience, similar work performed, personnel qualifications and backgrounds necessary for the manufacture of the Mobile Launch Vehicle Chassis.

PD will provide the PD Statement of Capabilities document that provides evidence of PD’s experience in design for dynamic vehicle structures and launch platforms. Past Performance

3.2.4.3 A documented track record showing its ability to meet critical end dates and manufacturing schedules.

PD is not currently scoped to perform any manufacturing of the MLV. PD will provide the Design Statement of Capabilities document that provides evidence of PD’s experience in design for dynamic vehicle structures and launch platforms.

Past Performance

3.2.4.4 Adequate plant capacity and labor resources to ensure satisfactory completion of the proposed scope of work.

PD will provide the PD Statement of Capabilities document that provides evidence of PD’s experience in design for dynamic vehicle structures and launch platforms.

Proposal Documentation

3.2.4 Specific Contractors Qualifications

3.2.3 Life Cycle

3.2.2 Clearances

3.3 SCHEDULE REQUIREMENTS

3.3

The contractor shall specify and control design, manufacture, testing, delivery, and receipt of the units The Contractor shall provide a schedule within two (2) weeks of contract award for both design and manufacturing phases. Refer to section 4.0 for additional schedule requirements details.

PD has provided a schedule that includes milestone meetings and reviews. PD will follow this schedule and alert stakeholders if there is an issue meeting a certain date.

Proposal Documentation

3.4.1

The Contractor shall identify, to the BPO/NASA representative during the Design phase and to the PD subcontracts administrator during the fabrication phase, any recommended work, and associated costs to perform the work as indicated:

Specified work which does not meet the requirements of specifications referenced in Section 2.0 of this specification.

If any designs do not appear to be able to meet requirements listed out in Section 2.0 of the 820- REQ-13 MLV Chassis Req 02.24.23 document, PD will immediately notify CSBF who will then notify BPO of the concerns. The concerns can then be addressed via email or follow on meetings as appropriate.

Email Correspondence

3.4.2

The Contractor shall identify, to the BPO/NASA representative during the Design phase and to the PD subcontracts administrator during the fabrication phase, any recommended work, and associated costs to perform the work as indicated:

Safety hazards discovered during manufacture, or within approved drawings or anticipated for future maintenance.

If any hazards are identified during the design phase. They will be itemized and listed out in a hazards summary. Design

3.4.3

The Contractor shall identify, to the BPO/NASA representative during the Design phase and to the PD subcontracts administrator during the fabrication phase, any recommended work, and associated costs to perform the work as indicated:

Any perceived problem not designated above.

Any other problems that are identified during the design process, PD will notify CSBF and BPO of the concerns via email and follow-up meetings as required.

Email Correspondence

3.4.4

The Contractor shall identify, to the BPO/NASA representative during the Design phase and to the PD subcontracts administrator during the fabrication phase, any recommended work, and associated costs to perform the work as indicated:

Any other work that the Contractor believes to be out of scope.

Any work that is perceived to be out of scope (Governed by Schedule A and B of the Statement of Work), PD will notify CSBF and BPO of the concerns via email and follow-up meetings as required.

Email Correspondence

3.5.1

The Mobile Launch Vehicle Chassis shall satisfy all Occupational Safety and Health Administration (OSHA) requirements for hand railings, steps, and any other applicable sections specifically on the fully extended launch boom and Mobile Launch Vehicle catwalks. The railing or system shall be designed in such a way that it does NOT present an entanglement source to the flight train (strands of wirerope).

PD will use OSHA 29CFR 1910 sub part d as the requirements basis for all steps, ladders, and railing. Design

3.5.2 Passive mechanical safety devices shall be utilized when applicable. PD will design in passive mechanical safety devices (such as kick plates, guards, and other devices) in all applicable locations. Design

3.5.3

Any areas such as the payload deck area that requires access while a guardrail is down or not present (open edge) shall have an OSHA/ANSI Z359 Series compliant restraint point for personnel to anchor to for fall restraint (at minimum).

PD will design any areas that require access while a guardrail is down or not present (open edge) to have the appropriate attachment or anchor points for the Z359 Safety Harness Series as governed by the OSHA requirement 1910.140.

Design

3.5 SAFETY REQUIREMENTS

3.6 DESIGN REQUIREMENTS

3.4 REQUEST FOR INFORMATION

3.6.1

The intent of this specification is to provide design and performance requirements to develop and build a Mobile Launch Vehicle Chassis of adequate capability with low maintenance requirements and operating costs.

The Contractor shall make efforts to minimize the overall cost of the project, including adherence to commercial-build utilization where possible, while ensuring that performance, reliability, safety, and maintainability requirements are met. A brief conceptual design shall be included in the proposal.

PD will use Model Based Systems Engineering Practices (as outlined in the NASA Systems Engineering Handbook) in tandem with project management techniques to identify, categorize, and mitigate project risks to reduce cost and maintain the agreed upon schedule.

Any deviations or risks identified will be communicated with BPO via CSBF and tracked using a risk register that will be presented at both PDR and CDR.

The final risk register will be delivered to the end user as a deliverable in the final documentation package.

Design and Risk Matrix

3.6.2

The key consideration in designing the Mobile Launch Vehicle Chassis is to understand the chosen commercial-off- the-shelf (COTS) power plant. This document requires the use of a Caterpillar 966M Wheel Loader selected based on a brief industry study of availability. The contractor has the responsibility to ensure that the power plant can integrate with the Mobile Launch Vehicle and meet all the requirements in this document. In the event that the Caterpillar 966M Wheel Loader cannot be integrated into the design, vendor shall notify BPO/NASA representative immediately and an in-depth justification will be required.

PD has received the specification sheet for the Caterpillar 966M Wheel Loader. The 966M will be the corner stone of the design foundation and will be kept at the front of the design consideration.

PD will continue to review at any design data provided for the Hercules or previous versions of the MLV to assist in the understanding of how the power plant interfaces and reacts to the MLV. PD also is in contact with Caterpillar directly regarding the design specifications and features of the 966M Wheel Loader and its various options.

Design and Analysis

3.6.3.1

In all cases, the design phase I drawing submittal phase will precede manufacturing or fabrication tasks. The engineering design drawings and schematics shall include but are not limited to the following:

- Mobile Launch Vehicle Chassis

- Specialized equipment and tooling required for operation and maintenance.

- Mobile Launch Vehicle Chassis systems schematics (braking, suspension, electrical)

- Hydraulic system schematic.

- Power systems and lighting schematic.

- Controls system schematic (alarms, emergency and safety features, process control, monitoring).

- Structural drawing package.

- Maintenance plan, electronic and hard copy; one set of each per vehicle delivered.

- Operation and assembly instructions, electronic and hard copy; one set of each per vehicle delivered.

- Power plant axle cart

- PD will provide a comprehensive drawing package that will include all structural assembly and part drawings, mechanical system schematics, power system schematics, and control system schematics. They will be organized in an agreed upon way such that the government can easily send the package out to vendors for quotes.

- PD will provide a comprehensive Maintenance plan that will highlight routine maintenance that will facilitate the MLV service life of 30 years (20 launch cycles per year).

- PD will provide a comprehensive operation and assembly manual.

- PD will provide a design package including assembly drawings, part drawings, and Bill of Materials for Commercial Off The Shelf (COTS) parts. Such that the government can procure and fabricate the system for use.

All Documentation will be released and controled in the PD CM system in accordance with configuration management plan.

Final Deliverable Documentation

3.6.3 Design Products

3.6.4 Hydraulic System Design

3.6.4.0

The Mobile Launch Vehicle Chassis Hydraulic system will have to be independent from the Power plant (loader) and shall maintain the ability to operate when fully disconnected to run chassis jacks and boom. This feature is required for service and assembly/disassembly. Additionally, it is highly desired to have the controlling hydraulic system contained within a serviceable pallet for ease of eventual maintenance and repairs. The pallet shall include manual independent controls for:

1. Boom – In and Out motion

2. Boom – Up and Down motion

3. Chassis – Up and Down Lift Jacks

Furthermore, a wireless hydraulic control module shall be included to account for:

1. Boom – In and Out motion

2. Boom – Up and Down motion

PD will design an independently operated (from the power plant) hydraulic system that will run:

- Chassis Jacks (pending trade study)

- Boom

- Any auxiliary systems

The Hydraulic system will be designed such that the system fits on a pallet (single tray with lifting points) such that the system can be easily removed and serviced as necessary. The pallet system will include the appropriate headers for hydraulics and electronics such that the system is compartmentalized.

The hydraulic system will have a local manual controls for:

- Boom in and out motion

- Boom up and down motion

- Chassis jacks up and down. (1 control for all jacks, pending trade study)

The hydraulic system will have a wireless control module for:

- Boom in and out motion

- Boom up and down motion

Design

3.6.4.1.1 Pistons shall be sized to the appropriate operational factors of safety as justified by the contractor.

PD will design the hydraulic pistons such that the factor of safety of operation is greater than or equal to 5:1. That number is derived from the OSHA standard 1926.753(e)(2) for Multiple lift rigging procedures which states “This capacity, certified by the manufacturer or a qualified rigger, shall be based on the manufacturer's specifications with a 5 to 1 safety factor for ALL components.”

Analysis

3.6.4.1.2 Pistons in boom structure shall incorporate appropriate, automatic safety measures to ensure safe operation and shutdown in the event of a hydraulic system failure.

PD will design the boom with automatic safety measures to ensure safe operation and shutdown in the event of a hydraulic system failure. Design

3.6.4.1.3 Pistons shall not be housed in boom structure; such that disassembly of the boom is required for maintenance.

PD will design the boom such that the hydraulic pistons are exterior to the boom structure and can be accessed for maintenance and servicing. Design

3.6.4.1.4 Positive blocks/lock-out points shall be incorporated in areas where equipment must be in a position that poses a crushing or pinch hazard to employees during maintenance or servicing.

PD will design the Hydraulic pistons with “kick-stand” or positive locking features to prevent crushing or pinch hazards to personnel during maintenance or servicing.

Design and Analysis

3.6.4.2.1 Hydraulic lines shall be sized to meet operational requirements laid out here as justified by the contractor.

Hydraulic lines shall be sized such that the Internal Diameter (ID) provides the appropriate flow rate (Gallons Per Minute [GPM]) and flow velocity (feet per second [fps]) to safely meet operational requirements as specified in SAE J517.

Analysis

3.6.4.2.2 Hydraulic lines shall be sized to the appropriate operational factors of safety as justified by the contractor.

Hydraulic lines shall be sized such that they have operational factors of safety of 4:1 as based off industry standard. Analysis

3.6.4.3.1 If the team decides to interface with the loader auxiliary hydraulics, the design team shall use the appropriate fittings that mate up with the existing auxiliary hydraulics of the 966M loader.”

IF PD decides to interface with any of the 966M Auxilary hydraulic systems, PD will use O-Ring face seal CAT hydraulic fittings to interface with the Loader. Design

3.6.4.3.2 Valves and caps shall be utilized to aid in assembly / disassembly to avoid undue spillage of hydraulic fluids.

PD will specify non-spill hydraulic quick couplers at key assembly/maintenance points, as well as dust caps and shut-off valves where needed. Design

3.6.4.4.1 Hydraulic lines shall be fabricated in lengths which are easily removed, easily transported, and configured to preclude unnecessary removal of hardware during maintenance. Metal lines shall be incorporated as much as possible.

PD will work with the operators and experienced personnel at CSBF to understand what lengths are considered easy to remove, transport, and store. PD will also work to identify the configuration of hardware to preclude removal or disassembly for maintenance. Metal lines will be used in all locations where possible.

Design

3.6.4.1 Pistons

3.6.4.2 Piping and Tubing

3.6.4.3 Connection

3.6.4.4 Pipe Runs

3.6.4.4.2 Hydraulic line runs shall be mounted and secured to prevent rubbing between components or other tubing as well as preventing rubbing with the chassis.

PD will design the run locations for the hydraulic lines such that no rubbing between components or other tubes as well as with the chassis. Tie down points will be used where appropriate to maintain the appropriate spacing and fix points to mitigate any risk of rubbing, chaffing, or pinching of the hydraulic lines per requirement 3.6.8.2 and leverage Parker 4300 manual for best design practices.

Design

3.6.4.4.3 Passive protection measures of hydraulic lines shall be utilized to prevent reasonably expected damage during normal operations, i.e. kick / cover plates.

PD will place passive protection measures such as cover plating, kick plates, and other preventative protection measures to protect exposed lines and hydraulic components, which can be removed for maintenance purposes.

Design

3.6.4.4.4 Hydraulic lines shall not pass through or be run inside chassis structure. PD will make the design such that all the hydraulic lines are not located inside any of the chassis structure. Design

3.6.4.4.5 Where feasible maintenance points, such as grease fittings, shall be designed to be accessible from the lowest level possible and not require personnel to be exposed to fall, crushing, or pinch hazards to access.

PD will ensure ease of servicability when positioning maintenance points. PD will document all grease fittings, oil ports, and maintentance locations which will be presented at the CDR and coordinated through out the design process, and documented in the assembly and maintenance procedure.

Design

3.6.5.1.1

It is the contractor’s responsibility to envelope and quantify conditions stated herein. Mobile Launch Vehicle Chassis shall be able to sustain operation in a cold, arid environment, such as a Sweden winter and will be bounded at -25 °C (-13 °F).

PD will specify components and design decisions such that the MLV Chassis is capable of sustained operation between -25° C to 40° C (-13° F to 104° F) Design

3.6.5.1.2 Mobile Launch Vehicle Chassis shall be able to sustain operation in a hot environment, such as a Texas or Australian summer and will be bounded at 40 °C (104 °F).

PD will specify components and design decisions such that the MLV Chassis is capable of sustained operation between -25° C to 40° C (-13° F to 104° F) Design

3.6.5.2 The unit shall be capable of meeting all flow and temperature requirements in humidity ranging from 10% to 100%, which shall include rain rates up to 2”/hour.

PD will specify components and design decisions such that the MLV Chassis is capable of sustained operation in humidity ranges of 10% to 100% and in rain rates up to 2" per hour. Design

3.6.5.3 Chassis shall be appropriately grounded to provide a safe operational environment in the case of a lightning strike.

PD will design in the appropriate lighting protection system with guidance from the latest version of NFPA 780. Design

3.6.6 Vendor shall refer to NASA-STD-5008B for guidance on corrosion protection of the Mobile Launch Vehicle Chassis.

PD has the NASA-STD-5008B document and will use it as a guide to make design decisions based off the requirements listed out in Section 4.0 of the NASA Standard, while keeping cost and manufacturability in mind for the design.

Design

3.6.7

All fuel used by and stored on the Mobile Launch Vehicle Chassis shall be independently plumbed to accommodate each subsystem requiring mechanical power. These subsystems are currently defined as a Gen Set and a separate engine to power the independent hydraulic system to support boom and chassis jacks

PD will design the fuel system such that it is plumbed for each independent subsystem (Gen Set and separate Engine for the hydraulic system). Design

3.6.7.1 Due to the duration of flight line operations, two auxiliary fuel tanks supporting the Gen Set and hydraulic engine may be required to meet the operational needs.

PD will determing fuel consumption and design in auxilary tanks for fuel as necessary. Analysis

3.6.7.1.1 Auxiliary Fuel tanks shall be located in such a way that it is easily plumbed to their respective systems.

PD will design the auxillary tanks such that they are co-located with their respective subsystems so they are more easily plumbed to feed that sub system. Design

3.6.7.1.2 The minimum operation time of Gen Set shall be 16 hours. PD will base fuel consumption on the Gen Set running for a minimum of 16 hours at full load. Analysis

3.6.5 Operational Environment

3.6.5.1 Temperature

3.6.6 Protective Coating

3.6.7 Fuel

3.6.7.1 Fuel Tank

3.6.5.2 Humidity

3.6.5.3 Lightning

3.6.7.1.3 The minimum operation time of hydraulic engine shall be 16 hours. PD will base fuel consumption of the hydraulic engine running for a minimum of 16 hours, at full load. Analysis

3.6.7.2.1 Fuel lines shall be fabricated in lengths which are easily removed, easily transported, and configured to preclude unnecessary removal of hardware during maintenance.

PD will work with the operators and experienced personnel at CSBF to understand what lengths are considered easy to remove, transport, and store. PD will also work to identify the configuration of hardware to preclude removal or disassembly for maintenance.

Design

3.6.7.2.2 Fuel line runs shall be mounted and secured to prevent rubbing between components or other tubing as well as preventing rubbing with the chassis.

PD will design the run locations for the fuel lines such that no rubbing between components or other tubes as well as with the chassis. Spacers and tie down points will be used where appropriate to maintain the appropriate spacing and fix points to mitigate any risk of rubbing, chaffing, or pinching of the fuel lines per requirement 3.6.8.2.

Design

3.6.7.2.3 Passive protection measures of fuel lines shall be utilized to prevent reasonably expected damage during normal operations, i.e. kick / cover plates.

PD will place passive protection measures such as cover plating, kick plates, and other preventative protection measures to protect exposed lines and fuel components, which can be removed for maintenance purposes.

Design

3.6.7.2.4 Fuel lines shall not pass through or be run inside chassis structure. PD will make the design such that all the fuel lines are not located inside any of the chassis structure. Design

3.6.8.1

The Mobile Launch Vehicle Chassis piping, tubing, and components exposed to the environment shall be designed to withstand the operational environment defined in this document. Protective coatings shall be used only in those cases where it is not feasible to prevent corrosion by selection of materials of construction. It is the sole responsibility of the contractor to justify the material selection, but metal lines are preferred.

- PD will use NASA-STD-5008B to provide the requirements for the corrosion protection of all componenets.

- PD will use the environment requirements (weather and loading) provided herein to guide engineering decisions based on how components will function in those environments.

- PD will leverage Parker 4300 manual for best design practices.

Design

3.6.8.2

As a general rule, piping and tubing shall not be relied upon to support the weight of components and pressure gauges. Tubing on the equipment shall be restrained and supported using tube clamps, preferably the split-block type and spaced no more than 3 feet apart.

PD will mount and bracket all piping and tubing components such as gauges, valves, and fittings to eliminate any loading induced into the tubing and hoses by those components. Design

3.6.8.3 All piping and tubing shall be fabricated in lengths which are easily removed, easily transported, and configured to preclude unnecessary removal of hardware during maintenance.

PD will work with the operators and experienced personnel at CSBF to understand what lengths are considered easy to remove, transport, and store. PD will also work to identify the configuration of hardware to preclude removal or disassembly for maintenance.

Design

3.6.8.4.1

Where flanged piping is used, the flange orientation shall be designed to minimize interferences with bolt installation and to provide adequate hand tool access. The piping system shall be designed such that individual components can be removed from the system (for maintenance or calibration) without dismantling or removal of adjacent components.

PD will evaluate all locations of flanged piping for tool clearance for not only the flange itself but any other hardware that needs to be accessed independent of the flanged tubing. Design

3.6.8.4.2 Ladders or platforms shall be incorporated in the design to aid in maintenance of equipment.

PD will evaluate the ability of a technician to reach equipment for maintenance and will provide platforms, ladders, or steps to easily reach and minimize level of effort for maintenance. Design

3.6.8.5 Passive protection measures of hydraulic lines shall be utilized to prevent reasonably expected damage during normal operations, i.e. kick / cover plates.

PD will place passive protection measures such as cover plating, kick plates, and other preventative protection measures to protect exposed lines and fuel components, which can be removed for maintenance purposes.

Design

3.6.8.6 Filters and gauges shall be located and oriented to allow for easy inspection.

PD will make sure that all filters are located in areas that are easily accessed and allow for tool clearance so that the filters can be easily removed and replaced for maintenance. All items will be identified in the Assembly and Maintenance Procedure.

Design

3.6.7.2 Piping Runs

3.6.8 Piping and Tubing

3.6.8.4 Accessibility

3.6.9 Auxiliary Engine

3.6.8.5 Protection

3.6.8.6 Filter and Gauges

3.6.9.1 The Mobile Launch Vehicle Chassis shall include a 12kw generator specified and adjustable to 120 V, 240 V and 50 Hz and 60 Hz.

-PD will specify the appropriate generator set to provide 12 kilowatts of power and be able to adjust from 120 V and 240 Volts.

- PD will attempt to find a generator that can be adjusted from 50 Hz to 60 Hz however, if the solution identified is not deemed cost effective by BPO, PD will specify a generator with a frequency generator to provide the ability to switch between frequencies.(Trade study)

Design

3.6.9.2 The generator shall have the same operation requirements as the Mobile Launch Vehicle Chassis.

PD will use the operation environment and time requirements listed herein to make engineering decisions for specifying the appropriate generator to meet BPO and CSBF's needs. Design

3.6.9.3 In accordance with GPR 1820.1C Section 1.9c, the lowest dB producing generator that meets the performance requirements shall be considered for selection.

PD will select an appropriate generator using GPR 1820.1C Section 1.9c as guidance to ensure that the system meets OSHA requirements for noise level exposure. (82 dB) Design

3.6.10.1 Electrical system shall be designed for the operational environment defined herein.

PD will use the operation environment and time requirements listed herein to make engineering decisions for specifying the appropriate electrical components to meet BPO and CSBF's needs. PD, upon final selection of components, will specify additional heating and cooling needs.

Design

3.6.10.2

The electrical system shall be designed such that individual components can be removed from the system (for maintenance or calibration) without dismantling or removal of adjacent components. Reusable disconnects shall be used whenever feasible.

PD will use the strategy of compartmentalisation of subsystems to make the electrical design such that components can be easily accessed and removed for maintenance or calibration without having to dismantle adjacent systems or components. Reusable connectors and electrical disconnectors will be used everywhere possible. Quick disconnect and DIN mount components will be used where practical to facilitate ease of maintenance.

Design

3.6.10.3.1 Electrical runs shall be mounted and secured to prevent rubbing between components or other tubing as well as preventing rubbing with the chassis.

PD will design the run locations for the electrical lines such that no rubbing between components or other tubes as well as with the chassis. Spacers and tie down points will be used where appropriate to maintain the appropriate spacing and fix points to mitigate any risk of rubbing, chaffing, or pinching of the electrical lines. PD will refer to Requirement 3.6.8.2 for guidance on securing electrical conduit or raceway.

Design

3.6.10.3.2 Passive protection measures of electrical runs shall be utilized to prevent reasonably expected damage during normal operations, i.e. kick / cover plates and conduit.

PD will place passive protection measures such as cover plating, kick plates, and other preventative protection measures to safeguard electrical wiring and components, which can be removable for maintenance purposes where practical.

Design

3.6.10.3.3 Electrical runs shall not pass through or be run inside chassis structure. PD will make the design such that all the electrical lines/runs are not located inside any of the chassis structure. Design

3.7.1 The Power Plant shall accommodate a wireless system to remotely control the launch boom hydraulic systems

PD will design the wireless remote control such that it has the ability to operate within the cab of the Power Plant and have a dedicated docking location within the Cab. Design

3.7.2 The wireless system control box shall accommodate an emergency shutoff button for all hydraulic systems.

PD will specify that the wireless system control box has a red emergency shutoff button (E-STOP) that will shut down the hydraulic system, and PD will verify that any instance in which the emergency button is initiated the hydraulic system will shut down in a safe state and not lose pressure or cause the boom or jacks to move unintentionally.

Design

3.7.3 The wireless system control box shall be electrically powered by the Power Plant.

PD will design the wireless system such that it is compatible with the Caterpillar 966M auxiliary power system. Design

3.7.4 The wireless system control box shall include gauges for the independent hydraulic system to monitor: Engine oil pressure, temperature, charging and hydraulic pressure and temperature.

PD is baselining a PLC controller system that would be able to communicate with a wireless HMI system inside the power plant. The HMI will be programmed by the fabriaction vendor (or sub contractor) such that it includes the following Gauges for the hydraulic system:

- Hydraulic system Engine oil pressure

- Hydraulic system Engine Temperature

- Hydraulic system Engine Battery Charging

- Hydraulic system Pressure

- Hydraulic System Temperature

Design

3.6.10.3 Electrical Runs

3.7 POWER PLANT INTERFACE

3.6.10 Electrical

3.8.1 The Mobile Launch Vehicle Chassis consists of four main components: the chassis structure, the launch deck, the electronic technician jump seat, and the launch boom

PD will use these terms for the four main sub assemblies for the MLV Chassis and will be shown in the documentation tree. Design

3.8.2

The chassis structure shall be designed to withstand the static and dynamic loads, both specified and implied here in. It is the contractor’s responsibility to determine and justify appropriate factors of safety. The Mobile Launch Vehicle Chassis shall have a life cycle of NO less than 30 years provided the manufacturer’s maintenance plan is followed and operations fall within the designed boundaries. The vendor shall provide exceptions to the 30-year life cycle, based on the consumable or perishable nature of components.

Maximum loading is predicted at 20 cycles annually.

PD will design the structure such that it can withstand the static and dynamic loads specified within the requirements document with a Factor of Safety (FOS) of 4 on service life as directed by NASA- STD-5005D section 5.1.2.d "Structures exposed to cyclic loads shall be designed for a minimum service life factor of 4 applied to the design life for fatigue assessments."

Maximum allowable stresses and design factors of safety will be leveraged from AISC 325 Steel Construction Manual in combination with Air Force Space Command Manual 91-710, as used by heritage PD fixed and mobile rocket launcher design and analyses.

Analysis

3.8.2.1.1.1

The Mobile Launch Vehicle Chassis shall be designed in such way that it can sustain typical transport loads via highway or sea vessel. Additionally, the Mobile Launch Vehicle Chassis shall be able to be lifted and loaded into a traditional transport vessel without compromising its integrity.

PD will design the MLV Chassis (without the loader interfaced) such that it can sustain typical transport loads (by highway or by sea) as specified in the MIL-STD-810H and MIL-STD-1320D standards. PD will provide the appriopriate pick points on the Chassis such that the whole Chassis (without the loader interfaced) can be lifted via crane and loaded onto a transport.

Analysis

3.8.2.1.1.2 The Mobile Launch Vehicle Chassis/Boom shall be able to lift a payload of at least 16,000 lbs. at its maximum extension and height.

PD will design and analyze the MLV Chassis and Boom such that it can lift a payload of at least 16,000 lbs at the booms maximum extension and height.

Design and Analysis

3.8.2.1.1.3

The Launch Boom shall contain mechanical safety device(s) that allows it to maintain and secure the boom, while maximally loaded, during the lift / extension and at maximum elevation / extension. (Figure 3, page 18 of 820- REQ-13 MLV Chassis Req 02.24.23_signed.pdf)

PD will design in mechanical safety devices such that the boom is secured while maximally loaded at any point in its elevation and extension such that if hydraulic pressure is lost the boom maintains its position without failing.

Design and Analysis

3.8.2.1.1.4

The Mobile Launch Vehicle (Chassis and Engine) shall be able to support the static loading conditions during inflation of up to 16,000 lbs of force while having a suspended payload weight of 8,000 lbs as shown in Figure 3 (page 18 of 820-REQ-13 MLV Chassis Req 02.24.23_signed.pdf). Loads shall be sustained at maximum height and extension of launch boom.

PD will analyze the MLV design under the static loading conditions as called out in Figure 3 of the requirement package which will include 16,000 lbs of force from the ballon lines plus the 8,000 lbs of the suspended load of the scientific gondola. PD will adjust the design as needed based off the results of the analysis.

Analysis

3.8.2.1.2.1

The Mobile Launch Vehicle shall be designed to sustain the following working loads shown in Figure 4 (page 19 of 820-REQ-13 MLV Chassis Req 02.24.23_signed.pdf, located here) at the “16 knot” load case. Additionally, margins shall be increased appropriately as described in NASA-STD-5005D to satisfy the load requirement and to prevent tipping of the Mobile Launch Vehicle while moving at a minimum speed range of 15 to 18 MPH.

PD will analyze the MLV design under the dynamic loads shown in figure 4 of the requirements document at the "16 knot" load case. The margins shall be increased appropriately as described in NASA-STD-5005D. Strength, Stability (tipping) , and Stiffness (buckling) analyses will be conducted on the load cases (LC) itemized below. Sub Load Cases will be conducted at Full forward Speed, Stopped, as well as full reverse, in addition to identifiing maximum expected forward, reverse, and turning accelerations (quasi-static load combinations). PD will also work with CSBF and NBOC to ensure adequate load enhacement factors (dynamic multiplication factors) are utilized to capture the transient nature of the loading.

-DLC1 - 16kt wind, 0deg crosswind -DLC2 - 16kt wind, 30deg crosswind -DLC3 - 10kt wind, 90deg crosswind

Analysis

3.8.2.1.2.2 Outriggers may be considered to help prevent tipping.

PD will analyze the MLV design for tipping while under the worst case loading scenario and determine if Outriggers are necessary. PD will present the tipping analysis and provide the design decision for stakeholder review. See 3.8.2.1.2.1 for initial load case summary

Design and Analysis

3.8 CHASSIS REQUIREMENTS

3.8.2.1 Loads

3.8.2.1.1 STATIC

3.8.2.1.2 DYNAMIC

3.8.2.1.2.3

Dynamic analyses shall include analysis of vehicle at top speed, both forward and reverse, with boom at worst-case loading and extension condition, tipping analysis, and loading under worst- case operational condition (at speed turning, hard braking, etc.).

PD will analyze the MLV design in dynamic environments that include top speed (18 MPH forward and 10 MPH in reverse) with the boom at worst-case loading and extension condition, worst-case tipping, and worst-case operational conditions. See 3.8.2.1.2.1 for initial load case summary

Analysis

3.8.2.1.2.4

The following launch scenarios (located on page 19 of 820-REQ-13 MLV Chassis Req 02.24.23_signed.pdf) shall be used for worse-case boom loading during launch regarding horizontal (Fx), vertical (Fy), and lateral (Fz) force vectors along with an associated resultant force vector. Each scenario uses the following assumptions:

• Balloon: A34.43-3H

• Gross Inflation: 14,406 lbf

• Drag Coefficients:

o Bubble = 2.3, o Rope Section = 2.3 o Aerodynamic Lift: Not Accounted

• For Net Lift: 8,510 lbf (gross lift minus balloon and flight train weight)

PD will use the provided scenarios and on page 19 of the requirements document to help define the worst-case scenarios that will feed into the analyses of the dynamic environments. See 3.8.2.1.2.1 for initial load case summary

Analysis

3.8.2.2.1 The Vehicle shall be capable of a minimum forward speed range of 15-18 MPH with the maximum suspended load at full boom extension.

PD has completed an initial analysis that indicates that if the MLV chassis remains below the indicated weight of 66,000 pounds that the vehicle will be able to maintain a speed of at least 18 MPH with a maximum suspended load of 8,000 pounds.

Analysis

3.8.2.2.2 The Vehicle shall be capable of a minimum Reverse speed of 10 MPH with the maximum suspended load at full boom extension.

PD has completed an initial analysis that indicates that if the MLV chassis remains below the indicated weight of 66,000 pounds that the vehicle will be able to maintain a speed of at least 10 MPH in revere with a maximum suspended load of 8,000 pounds.

Analysis

3.8.2.2.3 The Vehicle shall be capable of transitioning from forward to reverse and vice versa with minimum mechanical lag and no electronic lag.

PD will work with BPO via CSBF to understand the intent of this requirement, and make any design accomodations on the MLV to meet. It is outside the current scope of work to modify the 966M drivetrain capabilities.

Design

3.8.2.2.4 The transmission, overall acceleration will be as specified by the Caterpillar 966 M power train.

PD has done preliminary calculations of the accelerations with maximum load of 8,000 pounds and they are comparable to the accelerations provided by Caterpillar in their Specifications provided for the 966M

Analysis

3.8.2.2.5 The Mobile Launch Vehicle will be steered through an articulated junction and shall have a minimum turning angle of 37 degrees.

PD will make the design such that the steering is accomplished through the articulation of the 966M articulated junction. PD will verify the turning angle will be a minimum of 37 degrees, ensuring the proper clearance surrounding the articulated joint.

Design

3.8.3.1 The launch deck shall be large enough to accommodate at least 6 people across the width of the deck and have an unobstructed view of the front end of the vehicle.

PD will design the launch deck similar to the same design as the Swedish Hercules Launcher, and shall have a minimum standing area of 36 ft^2 Design

3.8.3.2 From the ground, the launch deck shall have a minimal deck height of 6 feet and allow an increase in height up to a minimum height of 12 feet.

PD will design a mechanism to allow the launch deck to elevate from a minimum of 6 feet to a minimum of 12 feet, via a scissorlift mechanism powered by the MLV hydraulic system. Design

3.8.3.3 Handrailing shall, per OSHA 29 CFR 1910.29, encompasses the perimeter of the launch deck with appropriate, self-closing gates at entrance points.

PD will design handrails and entrance points to the launch deck such that design satisfies the requirements listed herein and OSHA 29 CFR 1910.29, such as minimum required load carrying capacity.

Design and Analysis

3.8.2.2 Speed

3.8.3 Launch Deck

3.8.3.4

The Front Deck shall contain a protective metal cage enclosure for both stationary occupancy and occupancy at top speed.

a. Protective cage shall be constructed out of 2 inch by 2 inch mild box steel with an 1/8 inch wall or equivalent.

b. Protective cage shall be designed to accommodate the height of a 98th percentile male.

c. Protective cage shall be designed with appropriate stand-off from the handrail to prevent pinch points.

d. Protective cage shall be designed in such a way to allow the boom to be completely lowered and stowed but provide full perimeter protection when the boom is raised.

e. Protective cage shall include a horizontal member on the payload facing side at the level of the topmost member of the handrail. Centerline of this member shall fall within plus or minus the diameter of the handrail when measured vertically from the launch deck platform.

f. Protective cage shall employ overhead protection capable of protecting occupants from falling debris while providing visibility to balloon and payload.

PD will design the Front Deck (aka launch deck) with a metal cage enclosure for use during stationary and mobile operation at full speed that satisfies the following:

a. Cage tubing will be designed with cost and manufacturability in mind (availability, welding processes, etc) to meet an equivalent strength and stiffness of a mild steel in the form of 2" x 2" box tubing with 1/8 inch wall thickness.

b. The protective cage shall be designed such that it is 8 foot tall.

c. Cage design will provide a minimum of 4 feet stand-off distance to mitigate pinch points.

d. The cage will be designed similarly to the cage used on the Hercules MLV used in Sweden. The cage will have an opening for the boom while the boom is stowed and then the cage will be closed when the boom is elevated.

e. The cage will have a horizontal member located within one diameter of the top member of the hand rail as measure from launch deck

f. The cage will be designed similarly to the Hercules MLV used in Sweden. The cage will have overhead protection to prevent hazards from falling debris large enough to cause injury while still allowing for visibility of the balloon.

Design and Analysis

3.8.3.5 The Mobile Launch Vehicle chassis shall be able to provide a direct/hardline form of communication between the vehicle driver, the Electrical Technician Jump seat, and the Launch Deck located in the front of the vehicle.

PD will specify a hardline communications system that will connect to headsets local to the MLV Chassis and 966M Loader to allow the Electrical Technician (located at the Electrical Technician jump seat), 966M operator/driver, and personnel on the launch deck to communicate.

Design

3.8.3.6

The communication method shall be through “David Clark” hardwired headsets, and shall contain interface for a CSBF Provided Radio, located in proximity to the electronics cabin.