Abstract:
The system includes an assembly building of sufficient dimension to permit a launch vehicle to be vertically integrated within the building, and to simultaneously receive a combination launch pedestal-lift and transport unit within the building. The launch vehicle is vertically integrated within the building upon the pedestal, and then transported to the launch pad where the vertical height of the lift and transport unit is reduced, leaving the launch pedestal and vehicle in place at the launch pad. Various other features facilitate low cost launch programs using the system and method.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to systems and methods for launching spacecraft, and in particular to systems and methods for integrating the assembly, transportation and support of launch vehicles. 
     A number of systems and methods have been employed in the past for first conducting the assembly of spacecraft and launch vehicles,, then transporting the launch vehicle to a launch pad, and thereafter providing necessary support and testing before launch. In one arrangement utilized with the National Aeronautics and Space Administration&#39;s Saturn and Space Shuttle Programs, the launch vehicle is integrated vertically within the interior of a Vertical Assembly Building (VAB), and then moved to the launch site on a mobile transport unit, while the launch vehicle and spacecraft are positioned vertically upon the transport unit. 
     A mobile build up, transport and support system is disclosed in U.S. Pat. No. 4,771,998 to Rogge et al. In U.S. Pat. No. 4,363,257, Harris et al disclose a service assembly for a vertical launch system. 
     In the early days of the space and defense missile program, a variety of assemblies and facilities for launching and servicing spacecraft were used, including mechanical lay down towers and rail mounted launch towers. Assembly, transport and support systems which were relatively simple and economical in design were replaced by mobile service towers weighing several thousand tons, massive umbilical towers and large water cooled flame buckets contained within specialized concrete structures. The launch facilities presently used by NASA at the Kennedy Space Center are multifunctional, automated and sophisticated, but represent replacement costs in excess of two billion dollars. There is a need for an integrated system and method for assembling launch vehicles, and then for the rapid transport of the launch vehicle and payload to a clean, uncomplicated launch pad where launch support can be completed and the vehicle launched with a minimum of expense. 
     SUMMARY OF THE INVENTION 
     The system and method of the present invention has as its objectives means for permitting a launch vehicle and pay load to be vertically integrated directly upon the structure that will serve as the launch pedestal and platform, with the launch pedestal and platform being supported during the vertical integration phase by a mobile lift and transport unit. The launch pedestal assembly includes means for supporting the launch vehicle in a vertical position upon the platform, and interconnecting means for engagement with the lift and transport unit for lifting the entire weight of the launch platform and the launch vehicle vertically together. The lift and transport unit has corresponding means for engaging with the interconnecting means of the launch pedestal for vertically supporting the entire weight of the pedestal, launch vehicle and payload; in its preferred form, the lift and transport unit supports a vertical structure which is dimensioned to extend about the launch pedestal and launch vehicle and thereby provide access during the vertical integration of the various stages of the launch vehicle and payload. 
     In one form, the interconnecting means of the launch pedestal and the engaging means of the lift and transport unit comprise plural structural members extending generally horizontally from the launch pedestal, and plural corresponding horizontal support surfaces on the lift and transport unit, each of which is spaced and dimensioned to engage a corresponding structural member of the launch pedestal as the height of the lift and transport unit is adjusted vertically. 
     The vertical structure of the lift and transport unit includes a number of important features which facilitate the vertical integration of the launch vehicle and payload, the facile transport of the entire system to the launch pad and then continuing support of the launch vehicle as the lift and transport unit (and the related vertical structure) are moved away from the vehicle in preparation for launch. Among the features provided with the vertical structure are (a) means along the vertical structure for receiving elongated fuel and oxidizer transfer structures on opposing sides of the vertical structure, and removably coupling both the fuel and oxidizer transfer structures temporarily to the vertical structure during a fueling operation conducted at the launch pad; (b) plural horizontal platforms spaced vertically along the structure, each of which can be rotated away from the launch vehicle after placement at the launch pad; (c) a structural framework which is dimensioned to fit through an ingress-egress opening of the associated vertical assembly building; and (d) elevation means for permitting worker access to the various stages during vertical integration. 
     The vertical assembly building useful with the system and method of the present invention has dimensions sufficient to house the integrated launch pedestal-launch vehicle-lift and transport unit combination within the building, and having an ingress-egress opening dimensioned to permit the lift and transport unit with its associated vertical structure to move out of the building. The assembly building is spaced a distance from the associated launch site, and in one form, a number of Vertical Assembly Buildings support a single launch pad. A launch pad roadway is provided between the Vertical Assembly Building and the launch pad, and is sufficiently load-bearing to carry the combined weight of the lift and transport unit with its vertical structure, together with the launch pedestal and a vehicle mounted vertically upon the launch pedestal. Significantly, means are provided with the launch and transport unit-vertical structure combination for maintaining an umbilical cable connection as the lift and transport unit moves along the launch site roadway toward the launch pad, so that launch vehicle checks made through the umbilical cable at the assembly building need not be repeated at the launch pad. An appropriate storage trench or other appropriate means is placed along the roadway for storing the umbilical cable coupled between the lift and transport unit and the launch pedestal after the launch pedestal is appropriately placed at the launch pad, and before launch. Thus, the launch pad itself is free of complex structures built within the launch pad. Rather, a flame deflector (if needed) is provided at the base of the launch pedestal, thereby avoiding the need for a built-in flame deflector in the launch pad. 
     The launch pad is provided with anchors which receive the vertical risers of the launch pedestal assembly. Similarly, anchors across the foundation of the vertical assembly building are mated with and support a free-standing crane located within the assembly building, the crane defining an internal bay of sufficient dimension to receive the lift and transport unit and its associated vertical structure. 
     These and other important features of the present invention will be understood with reference to the accompanying drawing, and the following detailed description. 
    
    
     THE DRAWING 
     FIG. 1 is a perspective view illustrating the principal elements of the launch access, transportation and support system of the present invention. 
     FIG. 2 is a front elevation of a vertical assembly building useful with the system of the present invention, with a portion of the outer skin of the building cut away for illustration purposes. 
     FIG. 3 is a cross section of the building construction shown in FIG. 2, taken along the line 3--3. 
     FIG. 4 is a perspective view illustrating the foundation of the assembly building shown in FIGS. 2 and 3. 
     FIG. 5 is a perspective view illustrating the freestanding crane mounted upon the foundation shown in FIG. 4, and within the assembly building depicted in FIGS. 2 and 3; the lift and transport unit and its associated vertical structure is also depicted in FIG. 5, illustrating the manner in which that assembly is received within the bay of the free-standing crane. 
     FIG. 6 is a perspective view illustrating a roadway and launch pad. 
     FIGS. 7 and 8 are front and side views, respectively, illustrating the launch pedestal assembly of the present invention as mounted at the launch pad, and with the launch vehicle mounted upon the pedestal assembly. 
     FIGS. 9 and 10 are front and side elevations, respectively, illustrating the integrated launch pedestal and lift and transport unit combination. 
     FIG. 11 is a perspective view illustrating the lift and transport unit together with its vertical structure after the pedestal-launch vehicle combination has been properly placed at the launch pad. 
     FIG. 12 is a perspective view of a portion of the launch pedestal and lift and transport unit assemblies. 
     FIGS. 13 and 14 are perspective views illustrating details of the unit of FIGS. 9-12. 
     FIG. 15 is a perspective view showing the manner in which the lift and transport unit and the pedestal are positioned within the bay of the crane during the vertical integration phase. 
     FIG. 16 is a side view of a fuel/oxidizer transfer structure. 
     FIG. 17 is a perspective view of a portion of the structure shown in FIG. 18. 
     FIG. 18 is a perspective view illustrating the manner in which the fuel and oxidizer transfer structures are used during a fueling procedure. 
     FIG. 19 is a perspective view illustrating a multiple vehicle assembly building layout for use with a single launch pad in accordance with the present invention. 
    
    
     In the various views of the drawing, two digit reference numerals are used to indicate major assemblies of the system, and three digit numbers are used to indicate specific elements associated with each assembly. The three digit reference numbers use the same first digit as the associated major assembly; for example, vertical assembly building 20 (a major assembly) includes structural framework 212, building skin 216 and doors 218 as elements of that major assembly. 
     DETAILED DESCRIPTION 
     The following contains an overall description of the major components of the system of the present invention, and is followed by a detailed description of each major assembly and the manner in which these individual assemblies interrelate together. 
     A. Principal Components of the System 
     Referring first to FIG. 1, the system of the present invention, referred to generally by the reference numeral 10, includes a vertical assembly building 20, a launch pad 30 spaced some distance away from the building 20 and with a load-bearing roadway 40 between the building 20 and the launch pad 30. The system 10 has as its principal purpose the vertical integration of a launch vehicle 50, and then the transporting of the vehicle to the launch pad 30, and for thereafter supporting the vehicle during the launch phase. To this end, there is provided a launch pedestal 60 upon which the vehicle 50 is initially vertically integrated within the building 20 while positioned within the vertical structure of a lift and transport unit 70 in a manner described in greater detail below. 
     B. Vehicle Assembly Building and Free-Standing Crane Structure 
     Reference is now made to FIGS. 2-5. The vertical assembly building 20 is positioned on a foundation 420 having fixed anchors 422 for supporting a free-standing crane structure 220 (note FIGS. 4 and 5). The building 20 includes a vertical structural framework 212 and a ceiling framework 210, all of which is covered with a skin 216. The building 20 defines an ingress-egress opening 214 and a pair of doors 218 which permit the opening 214 to be closed. 
     As shown in FIG. 5, the free-standing crane 220 includes a plurality of vertical supports 222 connected to the anchors 422, the crane 220 further including horizontal supports 224, and a movable horizontal rail 226 with an overhead hoist 228. The crane 220 defines a central bay 230 of sufficient dimension to permit the lift and transport unit 70 and its associated vertical structure (described in greater detail below) to fit within the bay 230. 
     It will thus be understood from a review of FIGS. 2-5 that the launch vehicle So is initially vertically integrated within the building 20 while positioned inside the bay 230 of the free-standing crane 220, and further included within the vertical structure of the lift and transport unit 70. 
     C. Roadway and Launch Pad 
     Referring to FIGS. 1 and 6, the roadway 40 between the assembly building 20 and the launch pad 30 is sufficiently load-bearing to carry the combined weight of the lift and transport unit together with its vertical structure, a launch pedestal (described in greater detail below with reference to FIGS. 7 and 8), and the launch vehicle mounted vertically upon the launch pedestal. As shown in FIG. 6, a portion of the roadway 40 includes a recess 310 for receiving an umbilical cable 642 for coupling between the lift and transport unit 70 and the launch vehicle 50. 
     The launch pad 30 includes plural below-ground anchors 320 for receiving the ground support legs of the launch pedestal 60; otherwise, the surface of the launch pad 30 is free of any fixed flame deflector structure, as the flame deflector is integrated with the launch pedestal, as described next. 
     D. Portable Launch Pedestal, Umbilical Tower and Deflector Structure 
     Reference is now made to FIG. 7 and 8. The launch pedestal 60 includes plural ground support legs 610 which are dimensioned to fit with the anchors 320 on the launch pad 30. The ground support legs 610 are coupled with horizontal supports 616, each of which has an extension portion 614 which permits the interconnection and engagement with the lift and transport unit 70, for lifting the pedestal 60 and the associated launch vehicle 50 vertically together, as is described below in greater detail with reference to FIGS. 9-12. 
     A flame deflector 632 is positioned across the horizontal support 616, and a launch platform 630 is supported by the pedestal 60 above the flame deflector 632 by vertical supports 620, horizontal supports 628 and struts 6241 626. The launch platform 630 is dimensioned for interconnection with a launch mount 510, which accompanies the booster section of the launch vehicle and does not form a part of this invention. 
     E. Lift and Transport Unit, and Associated Vertical Structure 
     Details of the lift and transport unit 70 and its associated vertical structure will now be described with reference to FIGS. 9-14. 
     The lift and transport unit 70 includes a horizontal platform 710 and associated load-bearing wheels 712. The platform 710 may be assembled from commercially available heavy load transport systems which may be integrated together. Suitable heavy load transport systems are manufactured by the Scheuerle Company of Pfedelbach, Germany. The transport units which form the base of the lift and transport unit 70 have the platform 710 fabricated across the multiple transport units in a generally U-configuration, so that a vertical structure is supported upon the platform 710, described below. Each load-bearing wheel 712 is supported by the platform 710 by a hydraulic unit 714, each of which includes a pair of brackets 715, 716 which are pivoted together at 713 and actuated by a hydraulic cylinder 718 (see FIGS. 13 and 14). 
     The lift and transport unit 70 further includes a vertical structure defined by vertical supports 720, cross members 722 and horizontal supports 724 which are constructed so as to define a central bay 726. The central bay 726 has a generally U-shaped configuration along its length, and is dimensioned so as to receive both the launch pedestal 60 and the integrated launch vehicle 50 supported upon the pedestal. 
     The lift and transport unit 70 further includes plural platforms spaced along the bay 726, each platform defined by two plates 728, 730 which are rotatably fixed along a corresponding vertical support 720, and have a shape which permits the plates to extend generally horizontally about the umbilical tower 640 and the launch vehicle 50. (See FIG. 11) . The platforms 728, 730 permit personnel to work upon the various stages of the launch vehicle, including its upper pay load. 
     As shown in FIGS. 10 and 11, the lift and transport unit 70 also includes a vertical service structure defined by ancillary vertical supports 750 having an overhead elevator motor 752, elevator cable 754 and elevator 756 supported therein, together with stairs 760, all of which permit access by appropriate personnel to the various stages of the launch vehicle 50. 
     As is specifically shown in FIGS. 9 and 12, the lift and transport unit 70 includes horizontal support surfaces 714 which are adapted to engage the horizontal extensions 614 of the pedestal 60 by operation of the hydraulic elevation mechanism described above and shown in FIGS. 13 and 14, which permit the entire platform 710 to be either reduced in height, or elevated. Thus, the platform 710 is reduced in elevation (without the pedestal 60 within the bay 726), and the unit 70 is then moved forward so that the extensions 614 are positioned over the support surfaces 714. Thereafter, the hydraulic means with the unit 70 are actuated to lift the entire platform 710, and at the same time elevate the pedestal 60. The entire assembly of the pedestal 60 may then be moved as required, e.g., moved into the assembly building 20, for vertical integration of a launch vehicle 50 upon the pedestal 60; or, alternatively, if the launch vehicle 50 has already been assembled upon the pedestal 60, then the entire combination may be moved to the launch pad 30 for launch operations. 
     An important aspect of the present invention is the ability to conduct tests through the umbilical cable 642 while connected to the launch vehicle 50 in the assembly building 20, and thereafter maintaining the connection of the umbilical cable to the launch vehicle 50 during transport to the launch site, and through the launch phase. This may be achieved with means with the unit 70 which handles excess portions of the umbilical cable 642 by storing that excess during the horizontal transport, and permitting the cable to be &#34;played&#34; through the handling means during movement between the assembly building 20 and the launch pad 30. Conventional cable reels at the back of the unit 70 are suitable for this purpose. 
     F. Portable Propellant Loading Assembly 
     For safety reasons, it is customary to load the launch vehicle 50 with a fuel and an oxidizer away from the assembly building 20. In accordance with the present invention, this may be undertaken on the launch pad 30 at a time before launch. To this end, there is provided a portable propellant loading assembly referred to in FIGS. 6-18 by the reference numeral 80. The loading assembly 80 includes a prime mover 812 having a load bed 814 with a retractable propellant transfer structure 820 pivotally mounted on the bed 814. In use, the structure 820 is pivoted along one side of a vertical structure 720 associated with the unit 70, as shown in FIG. 18. As further depicted in FIG. 18, two of the units 80 may be utilized along opposing sides of the vertical structure of the unit 70, so that one structure 820 may be utilized for loading fuel from tanker 830, and a second transfer structure 840 positioned along a second side for loading oxidizer from a separate tanker 850. 
     As shown in FIG. 17, the transfer structure 820 includes elongated supports 822 and attachment legs 824 for facilitating joinder with the vertical support 720 of the unit 70. Fuel/oxidizer lines 826 extend through the structure 820, and include quick connect-disconnect couplers at either end. 
     G. Multiple Assembly Building Configuration 
     The system 10 of the present invention particularly lends itself well to use in a multiple assembly building configuration of the type shown in FIG. 19. There, plural assembly buildings 20 are shown spaced around a single launch pad 30, with a separate roadway between each assembly 20 and the launch pad 30. The plurality of assembly buildings 20 may each be supported by a combined launch pedestal-lift unit combination 60, 70 or alternatively may be supported with only two or three of those combinations, thereby further reducing the expense associated with multiple, staggered launches from a single launch pad. 
     This concludes the description of the preferred embodiments. A reading by those skilled in the art will bring to mind various changes without departing from the spirit and scope of the invention. It is intended, however, that the invention only be limited by the following appended claims.