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-• • 7 EP',.....-:0.0toxii z2o6..24. • -.-kJ( CONFIDENTIAL
ENADQUARTIRS RESEARCH AND DEVELOP/62M COMMAND 6

NOFORN

k 1

.1$ (ft cr.

_CONFOr 

.rk4%.1r.4r

r • " 3 0 OCT 198!

(uszasaarato Trims)

DISCOVERER

SPACE SYSTEM DEVELOPMENT PLAN

,)1)1-

‘,.)

.4/

1

15 Jammer 196o

REVIEW El ;I-bee-1414Q

B. A. Schriever

Lt. General, USAF

Commander

• MICIOTILIIED MI

SPECIAL HAMLIN REQUIRED

2/0T RELEASABLE TO FOREIGN

NATIONALS

1 :-? ViAL!:1i !'')T

.

C 

WILEIRn253

This domain' captains Intennetion T

alkaline the national defame of the United Sates within the meaning of the bplenoce Laws. Tide 18. MAC., Callen 793 and 794

, the tommilakh In any manner to on den of wh

unauthorked amen Is prohibited by low.
-1111111M CONFIDENTIAL

AIR FORCE BALLISTIC /ass= macs NOFORN.

AIR RIBEAROL. AND DBYSLOPO12 COMMAND

3 0 OCT 19€

15 January 1960

•

4‘"

Under the basic guidance provided by Bq MAY in APDAT message 96212, the

program described herein provides for a 29-vehicle series. The objectives of

the Discoverer program are to demonstrate the feasibility of the design, the

structural integrity, and the function of the Agena vehicle and operating

subsystems which include guidance and control, stabilization of vehicle onorbit, and the closed-loop =mend system; and to determine the techniques

and procedures for tracking, acquisition, and comma* of the vehicle on orbit,

and recovery of capsule from orbit. In addition to the obois t conduct

biomedical experiments which include 'the recovery of living specimens from

orbit by .capsule . ajection, re-entry, and recovery. Determine the compatibility

of the Thor-Agena combination. In the Alma "B" Vehicle, develop the single

restart capability; and demonstrate the double size tankage, and the extendedburn engine. Increased orbit life 'will be achieved by design improvements,

increased mephatis on reliability' and engtneering . feedback as a result of

increased experience.

A description of the ground facility network and a funding statement of

the PT 1960 financial plan and the 7I 1961 Budget Istiaate is included in

this development plan.

This development plan provides for the timely, economical and logical

accomplishment of the Digo:Terms BAD Program, consisting of 29 vehicles, The

Discoverer program provides a broad experiments]. base in equipment developments and operating technique for the SANDS and MIDAS 3Fogrees.

• Adequate funding' (PT 1960, $71.1 millions and FY 1961,

as described in the funding section of this devalOpeent planaggelli

in order to comply 'with the Eq MAP guidance far the continuation of the

Discoverer program.

EMI 01 2U/sail

FORMOW

0. J. BMA=

Major General, USA?

Ccemander

rnvrirt,rtr rf.- 5

NOFORN WDLPB-253

This deastmat contains iniennetten affecting dm WNW defense of the United tholes within the meaning of the Espionage Laws,

This IS, U.S.C, bonen 793 and 794. the transmission of whidt In any 'sonnet le an unouthetised person is prohibited by law.
"WM

AIR FORCE BALM= wesna DIVISION (ARDC)

=COMM

DEVILOPSZE PLAN

TARLI OF COMM 

PAGE

TITLE PAGE

FOREWORD ii

TABLE OP OMENSiii

=maw TICEIXOAL PROGRAM

Tab 1 - Beekgroaaa 1-1-1 - 1-1-2

Tab 2 • Design Characteristics I-2-1 - 1-2-15

Tab 3 - Contract Annex 1-3-1 - 1-3-3

Tab 4 - Schedule 1-4-1

Tab 5 d- Teat Annex I-5-1 - I-5-19

SECTION II - MOM PROGRAM II-1 -'11-4

SECTION Ill - mammas PROGRAM Ill-1 - 111-3

EMI

WMPR-253 iii

This demon. confabs Information effecting rational delves of the United Metes within the meaning of the Wangle Lows,

Title 111, U.S.C., Section 793 and 794, the transmission of which In any moaner to en unoutheetred person is prohibited by low.
1-1 I r."

DISCOVERER

BACKGROUND

The concept for using an Earth satellite as a Platform. for detecting,

measuringl 'and, tvansmitting significant scientific data to ground-'based

stations was a natural outgrowth of progress here and abroad with research.

rocket's. Thee • 

for timely and continuous scientific research utilizing

instrumented rockets and Earth satellites after the close of the International

Geophysical Year was also emphasized by the first conference oaths Internetional Geophysical Year held in the United States. The impetus whiclimoiirated

the United States Government to support new methods for collecting otherwise

unattainable scientific intormationwasman's rapidly increasing ability to

view the world as a whole. From these observations will came avast body of

scale aspects of the Earth: its exterior, the doter and upper atmosphere,

gravity andnagmetism, and extraterrestial features.

The results of nUmerous studies conducted since 1946 by American scientists

egrtahLithed that a satellite used'as a scientific data gathering medium was

feasible and would satisfy to a great extent therequitements of the scientist

for information.

The concept of the satellite research system is a result of studies conducted at the Rand. Corporation. A study completed in 1947 together with

similar investigations by other contractors concluded that such a satellite

system was feasible. In subsequent years further studies were conducted. by

the Government leading to the award in Octob er 1956 of a contract to Lockheed

Aircraft Corporation for the development and test of a satellite research

system. The following month, Massachusetts Institute of Technology was

awarded a contract for the research and devvibpsent of the guidance and

orbital attitude control equipment for the system.

• As the result of the Advanced Research Projects Agency (ARPA) Order No.

17-59, dated, 4 September 1958 with three subsequent amendments, he program

structure was established to provide for fifteen (15) ARPA funded flights.

ARPA Order Mo. 48-59,•aated 16 December 1958 confirmed previous instructionvto identify this program as DISCOVERER: thus, separating this development

from the overall WS 1171, program structure. A Discoverer Development Plan,

dated 30 January 1959, providing for a fifteen (15) vehicle program was

prepared and submitted for ARPA approval.

The 30 January 1959 Discoverer Plan was approved for a Thirteen (13)

vehicle program by Amendment No. 2 to ARPA Order 48-59, dated 24 March 1959.

WD•PR-253

I-I-1

This document contains Inferinatien ofhmting the notional defense States within the meaning of the Espionage laws.

This is, U.S.C., &Klan 793 and 794, the transmission of which in any monrat to on unauthorbed person is prohibited by law.
ifDLPR-253

1-1-2

Mai

In compliance with MAP message, MAT 59353, dated 27 iaxril 1959, a new

Discoverer Development Plan, dated 30 April 1959: calling for a twenty-five

(25) vehicle program was prepared and sulnnitted to the AIWA for approval.

The 25-vehicle program was approved by Amendment No. 4 to ARPA Order 48-59, dated

20 Noy 1959•

Amendment No. 6 to ARPA Order 48.60: dated 20 JUly 1959: increased the

Discoverer Program, from a 25-vehicle series to a 29-vehicle series. This intendment

included instructions to submit a revised Developnent and Funding. Plan to reflect

the program increase::

As the result of Department of Defense programming actions the Discoverer.

Programs was transferred froa the ARPA to REAP cognizance on 17 November 1959.

In response to Eq WAN', AFDAT message 1328/59, which required the preparation

of a new development plan for the transfer df the Discoverer program fro* the ARPA

to the Air Force, two Discoverer Denrelopnent Plans were prepared. The first

plan dated 1 December 1959 described a 29-vehicle Discoverer program. The second

dated 15 December 1959 provided for a 22-vehicle Discoverer programs within the

funding ceiling established by Eq DEAF in the above MAT message. As a result

of the presentation given to Eq REAP during 1445 December 1959, additional

guidance was received from Eq USAF in an AFDAT message 9E3212 dated 21 December

1959 to proceed with a 29-vehicle program, and to reduce the program funding

rate Idlers possible. The funding rate has been reduced by terminating operation

of the Annette Tracking 8tation reduction of the Spare Parts Program, and the

removal of the light weight thrust chamber for the Agena vehicle.

The plan to follow has been prepared in accordance with the guidance cited •

above for the continuation of the program.

This document contains infonnotion affecting lila r 7

so. within the enoanirc of Om Ispietwoo laws,

Ms IS, U.S.C., Section 793 and 794, Ma trannnistion d **Mt in any to an unauthottsod potion Is prohibited' by law.
DESIGN CHARACTERISTICS

I. INIRODUCT/ON

A. DISCOVERER MISSION

The Discoverer program is a research and development program

encompassing the development of a complex ground environment for the

design, development, testing, launch, orbit injection and an orbit

tracking and control of a large satellite vehicle, the Agena, with the

following immediate Objectives:

1. The achievement of orbital capability of the basic satellite

vehicle.

• 2. The development of operational system techniques and pro.

cedures.

The recovery of biomedical and other data from orbit through

the utilization of a suitable recovery capsule.

The execution of nonrecoverable advanced engineering tests,

The results of the Discoverer Program in the fora of experience,

techniques, procedures, facilities, the Agena vehicle and vehicle subsystem, and items of hardware will be directly applicable in whole or

in part to the Space weapons systems of SAMOS and MIDAS. Thus, Discoverer

provides a broad experimental base for future space programs.

A. unique and integral part of the Discoverer Program is the

6594th Test Wing (Satellite). This Air 'Ores unit is charged with the

responsibility of-preparations for and laundh of the satellites, tracking and command of the satellites on orbit, receiving satellite data

from on orbit and recovering receovery capsule from orbit.

B. OVERALL OPERATIONAL CHARACTERISTICS

Discoverer is ccaposed of an Agena satellite and a Thor booster.

In direct support of the Discoverer are launch, tracking and communications facilities.

After Thor burnout, the Agena and Thor sections separate. As

the booster falls away, the satellite vehicle continues in a self

stabilized, predetermined coast. At the termination of the coast phase

the internal satellite power plant activates, supplying the orbital toar49E,

WDLPR-253

1-2-1
•

•

1111111111/00r

WDEPR-253

1-2-2

CONFIDENTIAL #

TUB PAGE IB BLANK
velocity increment required to esteiblith a substantially circular orbit.

The internal controls then reorient the vehicle to the proper attitude.

The most common orbits pass within a few degrees of the poles.

As the vehicle orbits the earth and passes within range of the

ground tracking and acquisition stations, telemetry.signals are received

frees the orbiting vehicle and command signals are sent from the ground

station to exercise the =Omani and control portion of the Discoverer.

The orbit time of the Discoverer is approximately 90 mintues.

Because the orbit is essentially fixed in space and the earth rotates

inside it, successive passes over the earth's surface will be displaced

approximately 22i degrees at the equator. Useful operation of the

Discoverer will terminate upon recovery, When drag slow* the vehicle

and causes it to plunge into dense atmosphere, when the electrical power

supply is exhausted, or When a failure of equipment takes place.

II. DESIGN OBJECTIVES AID GENERAL OPERATING DATA

SATELLITE VEHICLE

The Agena satellite vehicle is being developed over a period, of

years and will include a variety of configurations, capabilities, and

useful satellite life spans. Development of the system will proceed

from a simple design of limited capability to a. more refined version

capable of greater scientific investigation.

SUBS1113110.3

General:

The over-all system de4elopsent has been divided into eight

subsystems which are identified as follows:

Airframe, Subsystem A

Propulsion, Subsystem B

Auxiliary Power, Subsystem C

Guidance and Control, Subsystem I

Comma ms1 Control, Subsystem B

Geophysical Environment, Subsystem J

Personnel, Subsystem K

Recovery System, Subsystem L

Airframe, Subystme A.

a. The Airframe Stibystea will consist of the propellant

and pressurization tankage, structures, aerodynamic fairings for the

satellite, a. destruct system, and all mechanical and e/ectrical installations in the satellite not specifically included in the definition of

other subsystems.

253
The Airframe will include a 60-inCh diameter cylindir

adapter (which will be attached to the booster and remain with it after

separation), and.the orbiting vehicle. The vehicle will be a 60-inch

diameter, load-carrying cylinder about 1n feet long, containing or

supporting all other subsystems. This cylinder will be inclosed for

about half its length in the adapter. The payload and structure on the

front of the vehicle will be protected from aerodynamic effects by a

conical nose section. The engine and pressurized gas storage will be

carried at the rear of the vehicle making an overall Ienght of about

18 feet. Nexiemm ytilization of structural material will assure the

highest possible ration of payload weight to gross weight. The overall

length will be increased to approximateiy 2611 Feet when extended.

. burn and large tanks are introduced into the progrms.

There are two general airframe configurations in the

Discoverer program:

(1) Single size propellant tanks used for flight

vehicles numbers one through 17.

18 through 29. (2) Double size propellant tanks for use with Vehicles

Beliabilit To assure maximum reliability, the Airframe Subsystem is signed with a Safety Factor in accord. with good

engineering practice. Further assurance of high reliability is attained

by subjection of the Airframe Stbsystem to qualification testing under

the appropriate structural and environmental specifications. The most

severe test conditions are simulated as accurately as possible to that

which the vehicle will encounter in use. Continuous reliability design

reviews will be conducted to improve reliability.

3. Propulsion, Subsystem B.

The Propulsion Subsystem will consist of the rocket

engine; pressurization; feeding and loading systems (other than propellant and gas tanks); the engine gimbals (but not gimbal actuators); and

the equipment required to start, stop, and control thrust magnitude in

response to an electrical signal from the ground or from the guidance

subsystem; and the equipment required to control the propellant flow

mixture ration. It will also include apy auxiliary devices required

to establish proper ullage orientation in the fluid system prior to

and during start of the main rocket engine, including the equipment

aiepaLred to operate these devices.

b. The Project Mistier 21E41, 15,1500poundpthzust, rim*

fed engine will be used for the main satellite rocket power plant. The

21E4141AF-3, using IRMA (inhibited red fUming nitric acid) and JP-4
propellants, having a 263-pound-second/pound vacuum •specific impulse,

will, be used in the first two Thor-boosted flights. The X1R-81-4-5

modified to use IRMA and SDI (unsymmetrical Dintethylhydrazine) es

prope/lants, has a 277-pound-second/pound vacuum specific impulse

end will be used on subsequent flights. The final engine configuretion will incorporate a 240 second burn time,. a restart capebility,

a 45:1 area ratio nozzle, and a triplet propellant injector which will

give a 268-pound-second/pound. vacuum specific ipU3.se. librces require:Ito provide proper fuel orientation prior to firing the main rocket .

engine at the completion of the coast These will be iiroded by small

20-second. duration, 120 pound thrust, .solid-propellant rockets (ullage

rockets). •

c. There axe . , four general engine configurations in the.

Discoverer Program: • .

The XLR-81-i3A-3 is used on the flight Vehicles 1 & 2.

The n&-8i-M-5 is used on flight Vehicles 3 through

through 21.

29.

The X1R,8141Ap.7 is used on flight Vehicles 18

The XLR-81-BA-9 is used on flight Vehicles 22 through

d.. Reliability: Primary and auxiliary propulsion deviceti

for this Subsystem will be developed, improved,- and modified. as necessary

to provide the degree of reliability for successful acccuplisiment.of

the mission. The highest degree of rellability assurance possible prior

to flight •will be attained through logical,time4, and extensive • develop

-ment testing of components, subassembliee assemblies, and the entire

subsystem under applicable enrironmental Conditions, to the degree that

it is possible to duplicate such conditions. Air Force technical management of this program will emphasize utilization of suitable test facilities and experience available at ARDC Centers as well as other institutiOna, civilian or military, during the prelaunch development and qualification phase. . • •

4.- Auxiliary Power, Subsystem C.

a. The Auxiliary Power Subsystem consists of equipment

required to supply electrical power toall subsystems within the satellite

vehicle from a time just prior to laundh - untii the end of the vehicle's

lifetime.

T.01004'- '

VDLPR453

1-2-5
•

,..c.,:cis4A-14 tipsier

b. The Discoverer Auxiliary Power System will be based on

the use of a nominal 28-volt battery power source, a 2-KC, 115-volt,

single-phase, general power ac distribution system, a 400-Cycle, 3-phase,

precision ac power system and a /.28 volt supply. The 2000-cycle se

inverter furnishes power for the ,L28 volt supply as well as power for a

+ 28-volt series booster regulator, operating from the ;rime energy •

source. The auxiliary power system will incorporate silver peroxide.::

wine batteries of refined design, yielding 72 watt-hours per pound..

Power conversion equipment will utilize power transistor inverters and

static transformer rectifier eopponents; due to the limitation of avail.

able electricel energy power conversion equipment of exceptionally

high efficiency is a requirement. Early paver inverters have an efficiency

of 65 percent and are adequate for initial test flights. An Improvement

program will be initiated for the development of controlled diode

inverters that show promise of considerably higher efficiency fbr liter

flights. The initial. Utilization of a photovoltaic power supply will be

made on at least . one flight to furnish 14-volt de power to the acquisition

beacon.

0. There are two general configurations of Auxiliary Power

used on the Discoverer. Thayer*:

Auxiliar y Poorer for 30 hour lifetime used on flight

Vehicles 1 through 17.

kudliary Power for 100 hour lifetime used on flight

Vehicles 18 through 29.

d. Reliability of the Auxiliary Power Subsystem will be

maintained and_improvellby:

Analyzing and rectifying the high failure rate

known to exist for auxiliary power systems components, particularly the

400 cps and the 2000 cps inverters.

Conducting diagnostic tests of these components

operated on the bench into actual loads with realistic on-off cycling

and with suitable instrumentation to observe internal transients and

abnormal behavior.

Conducting component and sdbsystea design improvement

program, utilizing redundancy, Berating parts, minimizing stress reducing

cagplexity and incorporating such other features as will. extend life time

without significantly degrading performance.

Isolating shorted or defective loads,,loss of which

will not be catastrophic, so that power will continue to be supplied to

operable portions of then' load.

WDLPR-253

1-24
Conducting component life tests in all significant];

different modes of operation, including on-off cycling, progressed power

levels, and/or continuous operation as applicable. Performing of these

tests with actual or suitably simulated loads and environment.

Broadening component specifications without

ambiguity to insure that all anticipated duty cycles and application

conditions are covered.

(7) Detersdning the extent to . which quality control has

been a factor in caxponent failures, and thus instituting more rigorous

inspection procedures. Initiating a bactrup production source if

warranted.

(3) Instituting more rigorous . procedures for reporting

the arms:stances associated with inverter failures, and 'taints/fling

historical.summary of experience with each model indica ting operating

time, repair, or rework accomplished, and 3rnown or probably cause of

failure.

(9) Extending cycle life testing of secondary batteries

to 10,000 cycles with appropriate depth of discharge and period; and.

d.etermini::g the engineering changes necessary to meet specified cycle

life.

5. Guidance and Control, Subsystem D.

The Guidance and Control fkibaystem will be comprised

of those items of equipsent•required to sense and direct vehicle attitude

and velocity so as to establish a satisfactory orbit.

In addition, it will:

Provide self-contained means for the initial alignment and maintenance of the desired vehicle attitude during orbital

operation.

Provide an indication of attitude, and rate of

change of attitude, to other subsystems in the vehicle as necessary.

c. There are two general configurations:

(1) 30.hour life

•

(2)-100 hour life

WDLPB -253

1-2-7
• .

d. Reliability: Maximum reliability of the Guidance and

Control Subsystem is being attained in the following manner:

Require all components such as gas jets, horizon

scanners, timers, etc. to perform satisfactorily under simulated environmental conditions, and. thus demonstrate a mean-time-to-failure (MITE)

compatible with requ ired life.

Use redundant components and circuits where weight

is tolerable and sufficiently great MTTF cannot be adequately assured.

For example, by use of back-up "D" timer signal for vehicle separation

from the booster and by programmed lockm.out signal to preclude premature

engine shutdown in case of accelerometer integrator malfunction—

(3) Require component failure reports during all phases

of testing to indicate failure areas, overhaul time, and replacement time.

6. Command and Control, .Subsystem R.

a. The Command. and Control Subsystem grand equipment

consists of those items of equipment required to perform the following

functions: •

Determine the position of a satellite vehicle

relative to the earth, as a function of time, by a process of observation and computation.

Command and program the functioning of the vehicle

payload and auxiliary devices on a time-sequence basis'or in real time.

Provide swans for communicating with the vehicle

from ground stations and for receiving and encoding environmental,

vehicle ftnctional and telemetry data from other vehicle subsystems.

Provide communications facilities. and terminal .

magnetic tape recording equipment ground installations for efficient

and reliable recording and transmission of received. information. .

(5) Provide a common time reference for the .vehicle

and ground. complex and a reference date-time index for the orbital

passes.

b. Subsystem ground equipment at tracking and acquisition

sites includes all non-airborne specialized equipment required. to

tranamit, receive, checkout and test, record, process, store, and decode

indexed information sato wmfeguard or otherwise perform functions at

the tracking and acquisition sites immediately subsequent to launch and

throughout the Discoverer's orbiting life.

c. The Discoverer ground-space communications program will

be based on a WA-band system.

WDIPR-253

1-2-8
7. Vehicle-Borne Ccmnunications 

The vehicle-borne communications subsystem shall consist

or:

S-Band-Tranorponder. The vehicle S-band transponder

supplies response pulses to the MICR! radar coded interrogations

which are used at the interrogating radar as a means of determining

vehicle position. The transponder also receives, decodes, and delivers

ground-to-air real-tine commands for operation of vehicle functions.

The 13-band transponder equipment includes a decoder and antenna.

Acquisition. Beacon. The acquisition beacon provides a

means for acquisition and tracking. This unit villoperate continuously

providing an acquisition signal for "back-up" in the event that other

acquisition methods prove unsuccessful. The transmiter is a low power,

crystal oontrolled, VIP, Cl/transmitter the output of which is duplexed

into a mason antenna with the VIP tela:etry transmitter. The acquiSition

beacon is isolated from the telemetry transmitter by means of a twoChannel diplexer.

Vehicle Timer-Progresseer. The elementary timer-programmer

is imbended to turn on a limited number of units of vehicle equipment

cyclically. Provisions are incorporated to include en initial cycle of

different omeposition_fromthe normal cycle. Commands from the ground

shall be capable of resetting and changing periods.

Vehicle Antennas. The vehicle sha/l be equipped. with

an 8..;band transponder antenna manly antennas for both the ascent and

orbit phases. The VBF ascent and orbit antennas shall be multiplexed

to serve both the telemeter transmitter and the acquisition beacon trans..

sitter.

e. BOK Telemeter. tte 1K/fl telemeter Shall be installed

to obtain and transmit vehicle functional,. environmental, and other

scientific data.

8. Geophysical ftviromaest k Subsystem 

a. This subsystem consists of the studies, equipments,

both rocket-borne and satellite-borne, required to provide environiental

data cOnsidered essential to insure and stsplify the design of a successful Advanced Reconnaissance Warted. This subsystem also includes the

ground equipment required to maintain, service, calibrate and checkout

prior to flight, those equipments described ebtive.

VDLPD.253

1-2-9
•

.6. . "

-CONFIDENTIAL.

b. Insufficient data exists on geophysical environment

to insure successful design and test of the satellite vehicles in the

following areas:

Atmospheric density

Cosmic radiation

Thermal environment

Meteor physics

Solar ultraviolet radiation

Atmospheric composition

9. Personnel, Subsystem K.

A personnel subsystem exists whenever any other subsystem,

or the booster subsystem, require the interaction of personnel. A

properly designed personnel subsystem consists of the following components:

Human engineering to insure optimum man-machine

compatibility.

Determination of the kinds and number of personnel

required to operate and maintain the associated. hardware subsystem.

c. Training and training equipment required. to obtain

suitably trained. personnel.

10. Recovery System, Subsystem I.

The Recovery Subsystem consists of a satellite-borne.

capsule, suitable payloads, and equipment that will collect and transmit

data by teleMetering and that will insure successful reentry and

recovery from orbit.

Design modifications shall be accomplished as required

to maintain the Eecovery Program current.

The recovery force in Hawaii will participate in a continuous training exercise which will be designed to develop to the highest

possible degree their searching proficiency, co-ordination, and air

anateh l and to provide a continuous testing mode for new recovery gear.

WDLPR-253

1-2-10
C. GROO) SUPPORT =MINT

The term "Ground Support li"t" refers to any or all

non-airborne implements or devices which are required at the launch

cagplex to inspect, test, adjust, calibrate, appraise, gage, measure

repair, overhaul, assemble, disaasenble, service, transport, safeguard,

record, store, actuate, or otherwise perform a function in support of

the air-borne vehicle prior to laundh.

The test ground support equipment shall be prototype

ground support equipaent. That equipment required for the Discoverer

Program is essentially the equipment already built and =land. Continuous

redesign, fabrication and test effort is necessary to modify, as required,

existing equipment to correct deficiencies as they arise

• D. BALIABILITT MORAN

1. Reliability Design Review

Continuous reliability design reviews are being conducted

within the funds available to assure equipment design for maximum

reliability. The major objective* of these reviews are: (a) To nsintain

a reliability prediction for the system concept so that decisions can

be made regarding the total permissible complexity at system level; (b) To

establish complexity values down to the equipment level; and (c) TO

assire that each equipment will meet its reliability goal.

The prediction techniques and part failure rates outlined

in such reports as BOA-TR 1100, RACC TX 58-81, and =TO 98 are used to

accomplish the foregoing objectives. The early prediction will be based

on the use of currently available parts, and assumed proper soli-cations.

Sams of the benefits obtained by use of the reliability review are as

follows:

Isolates marginal application of parts.

Identities marginal engineering design

Provides a basis for considering redundancy

Provides (Lamest:re of mean-tine-to-failure (WV)

e. Provides a detailed thermal evaluation of packaging

1• Bstablishes areas of therSal penalty

_._eoNRDErffpLL

NMI WDLPB-253

1-2-11

Ills document aenholns Intornolion eaten, the memo, dota ge of 1k. UMW the ma*. of the Stoloneee Lows.

TItle IleetIon 793 and 794, the tftlitinglINOR sIwhlthl.isqta,d pima Is prohibited by law.

- 1.4

... • :4'
Evaluates fail-safe features

Identifies parts for additional research and

development

Provides a measure of mean-time-to-repair OMR)

Defines probable modes of failure

k. Reveals use of non-standard fabrication processes

1. Reveals usage of unacceptable parts; i.e., parts known

to have unacceptable failure rates.

Eaperts in many specialties including parts, pests application, design, and fabrication are being used to effect reliability design

review.

2. Parts Program.

A comprehensive parts program is in progress to increase

the average life of piece parts used in the satellite equipment. This

program includes parts evaluation and establishment of application

criteria for the orbital environment. The major efforts to reduce part

failure rates include the following:

Selection of source and exact production line

Analysis of part instabilities

a. Circuit design to minimize the effects of these instam

bilities

Optimum denoting

Improved inspection techniques

A survey of parts application and developaent programs at

governmental agencies, subcontractors and vendors is presently being

made. This survey will be intensified. In addition, participation in

the Reliable Electronic Parts Program of Bette'. Memorial Institute will

continue, and the IMSD Data Interchange Program will be expanded to

include parts test data, specifications, and test plans. Information

obtained. from these sources, and other test data, will be used to prepare

parts list. This list and application data to be developed from the

parts study will be given to design personnel for their use in development work. The quality of all approved parts will be monitored. and

maintained by the quality control program. . It is anticipated that
Improved quality control acceptance criteria will permit ordering optimum

production batches from part suppliers. Acceptance Teat Specifications

and Acceptance Test Procedures will be analyzed to assure that only the

highest quality parts which meet stringent performance requirements are

purchased.

The part testing program is being oriented toward* establishmeut of failure modes, development of application data, and formualtion

of accelerated life tests. One task to be initiated will be to establish

the effects of cyclic and of continuous operation of active parts such

as transistors and microwave tubes. This study will be. correlated with

the effects of voltage transients, if possible. Efforts will also be

undertaken to develop techniques ;or detecting latent failures. Parts

are presently being evaluated in critical application areas and high

failure rates have been observed in the following parts:

Microwave tubes

Tantalite Capacitors

Connectors

R01078

Potentiometers

Diodes

Power transistors

Electron Tubes

i. Motors

The use of rotating parts such as 'imotore, slip rings, and

doling wheels will be minimized. In addition, valid state devices will

be developed to replace relays where feasible.

A fails* reporting system is being used to identity problem

areas in part applications. Same failed parts are selected for dissection

and analysis so that fabrication defects can be determined and. test and

application criteria can be established.

3. Materials and Processes Program

A study will be made to determine the degradation of materials

in a 'rectos. Such processes as wire wrap, solderless connectors, and

spot welding instead of soldering for part lead attacimmext, Till also be

investigated. CONFIDENTIAL

MEM IMIPR-253

1-2-13

Ilds document eentalns Interim:Mon affect., the national dame el die kised. glisincvslIbin the wassia# of the Espionage Laws.

T is u,Seaton 793 and 794, the tronsrolialon of vilids .ariiier!iii.iiriii . unaudierized pewee Is prohibited by law.
Assembly techniques will be developed to reduce stresses

to a minima during assembly. The need to alter the =figurations

of present parts to ease problems in this area will also be studies.

Specifications will be reviewed to prevent undesirable

reliability performance traceoffs.

4. Reliability Tests 

A considerable effort will be made to ascertain and measure

the environment of equipment. An extensive effort has already been made

to define the ground and launch environment of Discoverer. Studies will

continue on the effects on the following:

Electromagnetic Radiation

Cosmic Radiation

c. Radiation Belts

d. Interplanetary Dust

e. Vacuum

t. Weightlessness

The effects of these environmental factors =materials,

parts and cemponentsvillbe evaluated in IESD ground laboratory and

space laboratory programs using the criteria established in above study

of the unique space environment.

Reliability tests rill be comiucteWlat part, component and

subsystem levels. The types of tests that will be conducted are as

follows:

Accelerated life (parts)

Nominal life (system level)

Elevated environmental stress limits (parts and components)

Thermal cyclic and shock (parts and components undergoing

orbital thermal change)

Vacuum life (materials, parts, components)

Radiation life (particularly organic materials)

5. Communications Subsystem. Reliability (Subsystem B). Effort

will continue to establish and meet realistic-time-'phased reliability

requirements for earn. It is essential that the ultimate configuration

of SS/71 meet operational requiremeats in resod, to loss and distortion

of data, time inoperative, and accuracy of ephemeris determination.

It is also recognized that substantially accelerated. SSA reliability

growth and higher ultimate reliability goals can require markedly higher

funding -

MEER-253

1-2-14
6. Redundancy vs Weight Penalty Analysis Program.

Where the state-of-the-art peat life precludes achieving

the desirable equipment reliability goal, the use of redundant components

will be considered.. It is realized. that the use of redundancy is a poor

substitute for mature design and., therefore, duplicate components will not

be considered unless no other solution is feasible. The weight of each

redundant component and its associated contribution to enhance satellite

reliability will be considered in reaching a decision on each problem.

A stud; will be completed which will determine the optimum

use of redundant components with reference to the weight penalty: Some

components which may be considered for redundancy are as follows:

Inverters 68/C

Voltage limiter circuits

a. Electronics of the attitude control system SOD

d.. Data transmitter MA
SUMMARY DESCRIPTION OF CORTRACTS

A. AF 014647)-97 and AF 04(647)-347 Lockheed Aircraft Corporation

Management

LMSD: The central direction and control of concepts, studies

analyses, expenditures, programming, scheduling and reporting; the admini- •

strative support required to provide manning, funding and coordination

of all activities of the program; the source of evaluation and progress information to the customer. The responsibility for initiating, organizing, and

maintaining an adequate reliability program.

Systemi 

LMSD: Perform analyses, design studies and flight tests (and

basic development tests not applicable to a particular subsystem) in

determining compatibility of systems, establishing systaa concepts, design

criteria and constraints to ensure: compliance of space bound system components with the concepts for each successive system and complete systems

integration. This includes design, development and/or provision and

operation of ground equipment systems, ground-space tracking, communications, command systems and related test,. servicing, calibration and logistical

support equipment (both contractor and/or government furnished) embracing

human engineering and Q.P.R.I. studies as well as engineering research and

required manufacturing.

Subcontract: Conduct a progress of analytical study and system

simulation and conduct Alat studies.

Airframe Subsystem

LMSD: Develop and produce satellite airframe. Provide:

propellant and pressurization tankage; aerodynamic fairings; structural

supports, brackets and fittings; mechanical and electrical fittings not

included in other systems; environmental controls; and ground equipment

required for transporting, servicing, erecting and launching.

Propulsion Subsystem

LMSD: Obtain and integrate the orbital thrust rocket engine.

Develop and provide propulsion subsystem including: feed and loading systems,

engine gimbals, and eqpipment required to start and stop rocket engine in

response to command (or program) ullage orientation requirements, and

ground based items for testing, calibrating and servicing.

1.4

WDLFS-253

1-3-1

This deourant contains Infect/011w affocting the noticed deism of the Untied babe within the rnsentina of the Sapioneaa Laws,

Title IS, U.S.C., Whin 793 and 794, the Manumission of width in any many to an unouthotttod person Is prohibited by law.
Subcontract: Bell Aircraft Corporation: Modification and

development of ER-81 rocket to TiBm81-HA-3 (IRFNA and JP-4 propellants)

engine; performance of PFRT and delivery of ground and flight engines,

including spares, engine rework, engine repair and handbooks. Modification

and development of 7LR-81-BA-3 to IRINA and UDMH propellant configuration,

perform PFRT and delivery of ground and flight engines including spares,

engine rework, engine repair and handbooks. Modification and development

of improved engine to higher specific Impulse, and restart capability.

Aerojet-General: Design, develop and manufacture of solid

propellant ullage orientation rockets.

Auxiliary Power Subsystem

IMOD: Develop and/or provide and integrate: energy source and

power conversion equipment required to furnish electrical power for all

subsystems within satellite from time just prior to launch to mission's

ending and eqpipment required for testing and servicing.

Subcontract: Design, devalopaent and production of prime

energy souraraalair conversion eqpIpment, including power inverters,

voltage regulatora photovoltaic collectors, control relays and design,

and production O

gn

duction of primary and secondary batteries.

Guidance and Control Subsystem

IMOD: Develop and/or provide and integrate: ground based and

onboard guidance and control (comma) equipment required to stabilize,

direct, separate and boost orbiting vehicle and equipment required for

servicing, testing and calibration.

Subcontract: Design, development and production of horizon

scanners inertial reference package, control valves and nozzles, and.

MT inertial guidance system.

7. Ground-Space Communications Subsystem

MD: Develop andohniprovide and integrate and operate: Spaceground and ground communication and tracking equipment required by contractor

to Coordinate and monitor all flights and assist the government in detemmiang,

equipping and manning facilities required for service controlled activities.

This includes all ground support equipment required for servicing, testing

aM calibrating.

Subcontracts Pbilco Corporation: Conduct a program for

research, design, development and fabAscation effort for the ground space

communication subsystem and earli :OperitionOf. subsystem. manning and planning

of ground stations; and installation of'Subsystem H ground equipment.

--CONFIDENTIALWDLPR-253

1-3-2

This riecument conteins inlennetion effecting the natIonel *dem ef the Untied betas whhIn Win oraening of the IspIentrae Lows,

Title It U.S.C.. bellen 793 and 794, the nerionission of which In any meow to on uneulhadaed poison Is prohibited by low.
8. Biomedical Subsystem

LWSD: Develop a recoverable capsule to accomodate an aeromedical package for use with the Thor-boosted vehicles.

B. A? 04(647)-165 - Space Technology Laboratories, Remo-Woolridge Corp

Since Lockheed Aircraft Corporation has the prime contract under

the direction of AFDC, contribution of the Space Technology Laboratories

lies primarily in the area of consulting services and technical studies.

These services are performed for, ani at the specific request of MEND.

The STL studies are general in nature and indicate trends rather

than highly detailed final results. STL is not responsible for technical

direction, quiCUM1, of design, contractor performance, or contractor evaluation.

Responsible for providing such services as are required to adapt the

OM 75 booster, its facilities, ground support equipment, etc., to the

Discoverer and launch the combined SM 75 - Discoverer vehicle into orbit.

OA - 10, Air Force Cambridge Research Center

Responsible for conduct of a program of research and development

on equipments, techniques and methods for the collection of geophysical

environmental data. AFCRC has been delegated the responsibility for the

conduct of the program for the Geophysical Environment Subsystem.

KEPR 58 - 54_EavalAir Station, Moffett Field, California

Helium for 

C80 58 - 33, Ballistic Research Laboratory, Aberdeen, Maryland

Wind Tunnel Tests.

M1PR 59 - 73, Wavy, For Restoration and Modification of URNS Pvt. 

Joe E. Mann.

MME -253

1-3-3

This document contains information affeding the national defense ift the Willed ' within dm meaning of the fontanelle Laws.

Title 111, Section 793 and 794. ths nor/animism of which in any manner to an unauthorised person Is prohibited by law.
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ON
T PROGRAM

DMEICRIPTION OF MST PROGRAM

A. =MAL

1. Teat Philosophy

In any research and development program, the bridge from pure

theory to practical and reliable hatdware rests upon the keystone of an

adequate and balanced, testing program. That which provides both fern and

substance to the keystone is the teat philosophy. Thus, a worthwhile testing

program: must tegin, with a strong test philosophy. The test .philosophy must

have its origin in good engineering practice and previous experience

modified to meet the pboblem•under consideration. -

The development of a test philosophy for Discoverer has, as a

point of departure, the fund of knowledge resulting from the following:

The Ballistic Missibeftograms. These programs have provided

test philosophy, procedures, equipments, testing techniques; and the bdosiers

themselves which are used as the prime movers for the space programs.

The Manned Aircraft Programs. These programs have provided

tent philosophy, basic engineering and scientific principles of demonstrated

effectiveness.

From this storehouse of knowledge a space system test philosophy

has been derived which assures the rigorous testing of individual parts,

components, and subsystems up to and including the complete weapons system.

The Major lifference between previous test programa: and space test programs;

hence .

'

 the test philosophy/ iiathe problem of coMWUniedvehicle operation

in a spatial environment. Up to the point of o'bital injection, the

facilities beincepteAnd teehniqueállf the ballistic missile programs are

diiectly applicable to the test of space systems; once a space vehicle is

placed in orbit, the environmental and time functions become unique to

space and produce unique problems. Thus, maw new system elements east

be considered; therefore, generating many nor and varied testing procedures

for military space system.

Development testing of a space system has a, single purpose;

lo achieve a highly reliable system that satisfy the

system functional design objective. In a new'spece system such as

Discoverer, involving many new techniques and operating in a new environment; the system design must be detezminemithrough an iterative design

and test redesign process. The test program must be designed to insure

the prompt and complete engineering feedback of test information at all

development stages into the design and 'redesign phases: Both ground and

space system testing are developed on the building -10.06k Iainciple. For

--WDLPR-253

1-5-2

This document contains information effecting the national stow of the United Slates within the rneartio of the Ss peonage Lows,

Title it, U.S.C., Section 793 and 794, the tranonisdow

rr't 1101kitTC.:,_ iiger.999ierised person Is prohibited by low.

•n;* '
example, in the early phases of testing the simplest parts and components of an invidual sUbsysten are tested; as the testing program

proceeds in scope and complexity, additional subsystems are added until

the ultimate configuration is reached.

Primary dependence on flight testing to obtain design and

system parameters information is'recognized as inefficient and extremely

costly. Consequently, a comprehensive system of ground tests have been

initiated as a prerequisite to flight test. These tests, described

later in this test annex, have proven that ground testing of the space

elements of the system can be effective and economical. This requirement has, hoverer, established the requirement for new test facilities

and techniques in simulating systaa test environment. Many of these

facilities are located in the contractor's "backyard" and many are

Government ovned facilities used as they are available and suitable

for the tests to be conducted. These facilities also include new

Government facilities and equipments required to test the system. In

this type of testing the system can be operated over long periods of

time providing masses of statistical information to aid in the development of a reliable system. Ground testing under simulated system

test environment has limited usefulness, hovever, in that all of the

system environment cannot be simulated particularly as they apply to

the space vehicle and its functional subsysten. Temperatures, pressures

and shock caused by variations in these parameters can be simulated,

hammer, many parameters cannot be simulated, i.e., solar radiation

characteristics, Van Allen radiation belts affects - infinite-volume

vacklum, etc., these items must be tested on orbit. These factors plus

many others have lead • to the conclusion that a balance of testing must

be established between ground simulation and actual system tests on

orbit.

No testing is accomplished at any level if it can be done

more effectively at a lower level. However, the cost of a bit of

additional design data becomes increasingly expensive as a test at a

specific level is repeated over and over, until a point is reached

wherein the collection of a needed bit of design data becomes more

expensive to achieve in ground testing than it would by an actual systems

test. For example, early flight tests demonstrate the compatibility of

the boceterk the space vehicle; the guidance and control; and ground

space communications systems in addition specific design and operating

data are collected on the operation of other functional subsystems.

Relating the flight test program to the ground test program, the nuMber

of tests on the ground will represent an order of magnitude more testing than the flight test program. Thus any flight system test represents

tens of thousands of tests. an parts, components stbsystms, and system

simulation testing. Therefore, the test program looks like a pyramid,

schematically, with its broad base resting on the part and component

test progrmn. The types of testing accomplished are described in the

following sections. „.

WDLPR-253

1-5-3
IIIIPIIIIIIIP....

.. • 4- r '.

2. Test Description 

The basic test philosophy is that in all tests the progression

will be from the simple to the complex. This approach vill be followed

in the verification of components, equipments, subsystems, and the

complete vehicle system and ground facilities.

Another aspect to the Discoverer test program is that all.

vehicle equipments will undergo complete enviamemental,•proof, and

qaalification tests prior to installation in the vehicle. Further,

the vehicle itself viii. undergo static test firing prior to delivery

to the flight test base.

Certain flight tests will be concerned with the collection of

geophysical . andeirrironmental data for the design of future vehicle

configurations. These will include requirement for optical tracking

to provide precise orbital characteristics. Other tests will be concerned with verification of components, equipments and systems for

future. configurations.

• The Discoverer Flight Test Program involves flights using the

Thor booster for launching from Vandenberg AFB an a polar orbit.' The

objectives for Discoverer Progran are divided into four broad categories, namely, Awna vehicle and system operation testing, Agana/

Thor compatibility, and recovery capsule operation and testing.

The first flights are primarily engineering tests to establish

orbital capability and to detammiruelqamm/Thor compatibility, as well

as the first test of the complete system, including the tracking

stations.

The following flights will provide a gradual increase in the

test complexity by the addition of experimental capsules carrying

a variety of payloads and by more advanced engineering tests. The

, • test objectives will be governed in large part by the results of

previous experience and flight results, primarily refinement of recovery

of unique payloads from orbit.

WOLFS-253

1-5-4
-3

THIS PAGE IS BLANK

-etv-RDENTilt

WDLPR-253

1-5-5
CONFIDENTIAL

System Testing Responsibilities 

a. Support Testing. In support of the development design of

payloads and consequent vehicle design, the following design support

testing will be accomplished as required:

Wind tunnel tests

Environmental Tests

Recovery system tests

Propellant tank tests

Telemetry system tests

Ground support equipment tests

Roll control tests (Simulation)

Propulsion system altitude start tests

(9) Aircraft/ship data package snatch test

b. Camtive Testing. Douglas Aircraft Company will have the

responsibility for any component and captive testing on the Thor booster.

USD will provide captive testing for the Discoverer satellite vehicle in

the form of an inpiant systems run and a captive firing of each satellite

vehicle, less its recoverable payload, at the Santa Cruz Test Base. Fran

Santa Cruz, each vehicle will be delivered to the flight test launch area

at Vandenberg AFB.

c. Flight Testing. The responsibility for over-all technical

flight test direction and planning falls on IMOD: Preflight checkout

responsibility will be shared, hosvver, by DEM and Douglas Aircraft for

their respective vehicles and equipment. Douglas Aircraft Company will

have primary responsibility for design and construction of the launch

pad as the booster contractor. Discoverer system control will be vested

in the STC, Palo Alto, under direct Government cognizance, from which

control will be subrogated to other LE SD stations as the need arises

during an operation. Control functions will be transferred from Palo

Alto to the nevEMnnyvale Satellite Test Center facility in January 1960.

WDLPA -253

1-5-6
B. niggIAMMICEMM

Over-all Prom ObJectives 

The primary objectives of the Discoverer Program will be to

demonstrate: orbital capability and to obtain biomedical and advanced

engineering test data Zr the recoverable payloadcapsules.

Detailed Test ObJectives 

Detailed test objectives viii be prepared for each flight.

C. PLIGHT TEST MAN 

Vehicle 

The Discoverer Program utilises six different vehicle configurations as described in Tab 2, "resign Characteristics."

racilities 

• a. Over-all control of the Discoverer flight operations viii

be exercised by the Satellite Test Center (STC). Tio UNIVAC Scientific

1103 large-scale digital computers in Palo Alto will support, the STC,

converting binary tracking data to an ephemeris, issuing acquisition

data to tracking stations for subsequent passes, and predicting the

recovery area. The control functions carried on at the STC will be

transferred to the new-facility at Sunnyvale, California, in January

1960. Stations reporting direct/7 or indirectly to the OTC will be:

•The Vandenberg Control Center located at Vandenberg

APB, mhich controls blockhouse launch operations and Stations 2, 3,

and 8 below.

The Vandenberg Tracking Station.

The Vandenberg Auxilimy Tracking Station located at

Pt. Amu (Pt. Mugu Tracking Station).

Chiniak Tracking Station, Kodiak Island, Alaska.

Hawaii Tracking. Station, Oahu Island, T.E.

Hawaiian Control Center, Oahu Island., T.K.

Telemetry Ships.

Space Track, Bader, Doppler and Optical Tracking.

MDIPB-253

1-5-7
•

b. The Vandenberg and Hawaii Tracking Stations will use the

following equipment:

VERLOST (Modified Mod II) radar.

TIM-18 self-tracking telemetering antenna.

Tri-helix antenna.

Doppler range detection equipment.

Telemetry tape recording equipment.

Telemetry decammtstors for real time data presentation.

Plot boards for radar and TIM-18 tracking data.

Conversion equipment for teletype transmission of

radar, TIM-18, and doppler tracking data in binary format.

Acquisition programmer for pre-acquisition direction

of antennas.

Equipment for transmission of satellite commands.

c. The Chiniak Tracking Station will use the equipment listed

in 2 above, except that the TIM-18 antenna and associated equipment

are not provided. The radio signal reception functions of the TIM-18

antenna will be shifed to the tri-helix antenna already installed.

The Pt. Mugu Tracking Station will have the same configuration

as Chiniak above, and in addition will be equipped with a guidance

computer which determines and issues the necessary commands to initiate

and terminate second-stage baring at optimme times.

To provide more accurate orbital positional intonation for

the later flights of the Discoverer series, supplementary doppler

tracking methods will be employed. The exact time at which this additional capability will be available is under study. It is planned to

add appropriate doppler beacons to the Agena vehicles. Ground equipments will be provided by the modification of existing Discoverer

facilities, use of the cooperating facilities, or the'use of trailer

mounted receiving equipment.

f. A Recovery Force, presently consisting of nine C-119J

aircraft equipped with search gear, is stationed and is being maintained

MDLFR-253

1-5-8
at Rickam APB, Hawaii. Two Victory ships equipped with radio search

gear are also stationed in Hawaii. As needed, the Air Force will assign

four RC-121 radar picket aircraft to assist in the recovery operation.

ZINIMATELMTER

1.

Subject to the over-all management by the Air Force Ballistic

Missile Division, the LockbeedlMissile System Division (LMSD) has been

assigned responsible technical direction of the Discoverer Development

Program.. In accordance with ARDC Regulations, the NSW Weapons System

Project Office (WSPO) exercises technical test control of Discoverer

Systems tests. The Camiander, 6594th Test Wing, is the Systems Test

Controller who is assigned responsibility for exercising control of

the technical tests of the Discoverer during the test planning phase

and flight test operations. Within the broad direction established

by AFRO for Discoverer development, system revirements are generated

and integrated by IMSD, and appear as general and detailed test plans

and support requirements. Following project approval at AFRO, the

documents become official test plans with which all participants in

the program comply. The test operations are executed by LMOD and

Douglas Aircraft Company (DAC), the booster contractor, under the control

of the Systems Test Controller. In amoral, systems test direction and

execution is accasplished by IMOD personnel. In the case of the SK -75

booster, DAC personnel have been assigned responsibility for direction

and execution of booster activities. Test control and direction has

been established at each Discoverer field site, with the center of.

operations located at the Satellite Test Center (STC). Major decisions

concerned with such items as launch under marginal conditions will be

made at STC based on recamiendations made by various field stations.

In all cases, final authority in the areas of test control and direction

is at the STC.

Ezzalinguggau.

ORM

The system consisting of orbiting vehicle, launch and checkout

facilities, tracking stations, control centers, and computing facilities,

is considered as en operating entity and the functioning of each element

of the system is discussed as that element becomes active in the test.

BZILUNI

The basic planning, initiated several months prior to the

scheduled launch date, includes an adequate description of the test

CONFIDENTIAL WDLER -253

1-5-9
CONnDENTiAi:

configuration and test objectives. In addition, the specific plans

for attaining the objectives are explained. These plans thus represent

a summary discussion of the vehicle booster combination and the ground

station configuration as they are planned for any given flight.

F. lagilnialt422MEM

1. Vehicle

The complex nature of the satellite requires a constant

Checkout of components, subsystems, and systems to ascertain flight

readiness to attain the flight objectives. Equipment has been developed

for this checkout. Fran manufacturing, the vehicle goes through a

checkout period at STC during thioh components, subsystems, and the

system are checked to determine that they are operating properly and

that the vehicle is flight ready.

At Santa Cruz Test Base the vehicle is installed in a teat

stand and the engine operated. In the contractor facility at Vandenberg

AFB, the vehicle is win checked out, using equipment similar to that at

STC to determine flight readiness. The Vandenberg AFB facility is also

equipped to do major disassembly of the vehicle should the need arise.

On the launch pad, the blockhouse consoles maintain parameter checks

of the vehicle operating systems until the vehicle is launched.

c. The checkout equipment will be modified to suit changing

flight objectives and will be improved as test results permit operation

evaluation.

Tracking Stations 

The tracking stations undergo a continuous program of checkout

to maintain operational readiness. Local checks consist of internal

checks and aircraft "flyby" to assist in calibration. Prior to a

flight, or an anticipated orbit pass, the tracking station is checked

out in conjunction with the STC. As the Discoverer Program' progresses,

the tracking station equipment will be optimized, based on test results,

to increase reliability for tracking and data acquisition.

Satellite Test Center 

The Satellite Test Center (STC) maintains a constant program

of checkout with Vandenberg AFB launch base facilities and the tracking

stations. In addition, STC utilises as part of the testing the STC

Computer Center to generate an orbit ephemeris vhich is transmitted

to the tracking stations for equipment checkout.

WOLFS-253

I-5-10

COINF77.7.r
wt:)IVFIDEIVT* ;:.•

Recovery Force 

The air recovery of the capsules ejected from orbit requires

a separate test progrem to develop the direction finding and air

snatch equipment and procedures. An additional program of checkout

and continued training of this recovery force has been initiated.

The recovery equipment and direction tinder must undergo testing and

checkout prior to each flight tommalaize the probability of recovery.

In addition, aircraft crews will participate in a continuous training

program.

Recovery Capsule 

The recovery capsule is to be supplied by General Electric

to shit the Discoverer configuration. The test and checkout of the

capsule is a coordinated effort by G.B. and MD.

G. CCIERVICATICE MUM COUBTD0111 

Communication system countdown is initiated five hours before

impel), with a communication check to each station which also provides

a station readiness report and a time synchronization. Throughout

the countdown the OTC directs major activities of individual tracking

stations, the recovery force, and the launch base activities system

condition from individual status reports, and integrates separate

efforts into a coordinated, unified operation. The time relationship of individual station operations are planned, for a simultaneous

readiness condition of launch and tracking support equipment.

R. LefftaLJECLUILMMA(MOUSfila

The operation of the complete system fray the instant of launch

to the end of attitude stabilization on orbit is beyond the scope of

this plan; only a representative description is given here.

At the instant of lift-off, all booster/vehicle systems will

be operating.

Commencing with lift-off, the booster will be programmed to

roll until it atddns its nominal flight path azimuth. During this

period, the booster/vehicle will be in vertical flight.

After the roll programming is coepleted, the booster will be

programmed in pitch to hold a zero-lift trajectory Until the separation

attitude is reached. From then until separation a constant-attitude

trajectory will be programmed into the Discoverer control system.

-GGNf4aENTIAI.

WDLPR-253

1-5-11
mew

5. Separation occurs on attaining the proper altitude and attitude.

As the booster falls away, the satellite vehicle continues in a selfstablized, predetermined coast. At the termination of the coast phase,

the internal satellite pover plant activates, supplying the required

orbital velocity increment to establish a substantially circular orbit.

The internal controls will then erect the vehicle to the proper attitude.

I. gannuatgt.

The operations of the entire system during the period after

the vehicle is on orbit and stablised in attitude, and before the

time ahen the capsule is ejected, is described as the orbital phase.

All tracking stations of the Discoverer system conduct a

systematic equipment check prior to each vehicle contact. This exercise

serves to indicate the readiness of the station and verifies the

operability of its equipment.

J. RECOVERY OPERATION

Present planning provides that the recovery capsule will be ejected

from orbit to be air-recovered by C-119Jaircraft, in the ocean area

southsest of Hamaii.

MDLFR-253

1-5-12
8NCTION II - MST ANNEX

CC:WAND AHD CONTROL RESPONSIBILITIES AND PROS

A. 2111M

System command and control is a vorld-vide problem requiring

an extensive communication network. The actual functions of command

and control are not complex in themselves. The problem is made

complex because of the geographic separation of the various ground

stations and the need for reliable transmission of tracking and

systems, status data on a 24 hour basis.

The tasks to be accomplished in the command and control of.

the Discoverer test configurations include:

a. The collection and presentation of various types of data

that can serve as the basis for command generation.

b.. The refinement and analysis of selected data to permit its

employment in the decision or command determination process.

The definition and selection of emergency operational

modes in the event of system component failure.

The transmission of system commands.

e. The evaluation of system response to the commands and the

determination of required, modifications to scheduled command flow.

Central control authority mill be vested in the Satellite

Test Center (STC). A portion of this authority will be delegated to

the Vandenberg Control Center and to the Hawaiian Control Center for

the control of operations in thie local areas.

The degree to which control can be exercised over the system

is limited by the capability of the ground-to-vehicle command link

and by the high degree of system automaticity.

B. =Ma

1. The 8TC monitors the system checkout and the countdown during

the ;relaunch phases. Specifically, during the system, dry-run at X-2

days and again during the system countdown at T-5 hours, the STC

initiates the following activities:

a. Communication system checkout

CONFIDENTIAL

111

WDLTS-253

1-5-13
OONFIDENTIAL 111111111111111W

Simulation transmissions from tracking stations to the

computer center

Dry-run orbit calculation

d. System component repair and test rerun.

During the system countdown, the launch facilities aspects of

the countdown are under the direct control of the Vandenberg Control

Center. The STC in its direction of the over-all countdown, is

continually receiving and retransmitting system status information

and other pertinent data such as weather and recovery force status.

Vandenberg Control Center plots the important data received from

STC. In turn, Vandenberg Control Center continuously advises STC

of the status of the launch countdown.

The Hawaiian Control Center is also in constant contact with

STC during the countdown. Of particular concern to Hawaiian Control

Center is the estimated time of launch and the weather condition in

the planned impact area. The mission of all control centers during

this ;base clearly is to'establish the readiness of the uystea for

the planned flight. The decision to initiate or delay a launch is

made at the OTC. This decision can be made only after all the major

system components have been verified as operative.

C. MUNCH AND ASCRIT 

1. The STC functions during this phase are concerned primarily

with system coordination as follows:

The tracking stations are alerted and notified of initial

orbit parameters.

The Computer Center receives the times of vehicle engine

start and termination of orbital boost.

c. The recovery force is informed of orbit achievement and

redirected if required.

2. The Vandenberg Control Center functions are the diriat control

of the launch. facilities and vehicle command during this phase of the

test operation.

VELPR-253

1.5.14

$
D. ORBIT

1. The exercise of control over the vehicle in orbit is limited

to the following commands:

Reset of the orbit timer

Adjustment of the orbit timer

Control of orbit attitude and period

Initiation of the recovery sequence.

2. The intervals at which these commands are given are controlled

by the vehicle position in orbit relative to the tracking stations.

Therefore, the SW has very little freedom in command choice or

determination insofar as the vehicle, itself, is concerned. However,

it must continuously monitor the Discoverer system during the orbital

phase. Unexpected component failure in the vehicle or on the ground

will dictate a redetermination of the normal operational sequence.

Z. RECOVERY 

The decision to initiate recovery is made by the STC and the

command issued to the vehicle on orbit by one of the Discoverer tracking stations. The ships of the recovery force will previously have

been deployed to the predicted impact area prior to launch. The air

craft will have departed. shortly before the dump command is sent.

Fran this point on, Hawaiian Control Center becomes the focal point.

for the exercise of system control as delegated by OTC.

Progress of the search and recovery operation is plotted

against a predetermined. time schedule. Appropriate periods, which

have been established, following rigid safety standards, are allowed

for air and sea search. Changes in weather conditions are carefully

evaluated in terms of these predetermined standards. The RTC is

continuously informed of the progress of the recovery operation. Any

decision to postpone or halt the recovery attempt of the capsule search

will be made at STC on the basis of the information received from

Hawaiian Control Center.

F. ffEEKINTAjaana lef

A comprehensive evaluation of test results will be accomplished

at all appropriate levels.

MD -253

1-5-15
G. DATA FLOW

1. System teat data generatedvill be initially observed and

recorded at seven geographical locations as follows:

Vandenberg Air Force Base, California

Point Mugu, Naval Air Missile Test Center, California

Telemetry Ship, 950 nautical miles downrange

Mama Point TrimOdng Station, Ismail.

Chiniak Tracking Station, Alaska

Recovery Force, last of Hawaii

2. The types of data involved are:

Telemetry data

Radar tracking and control data

Launch (umbilical) data

Weather data

Prelaunch servicing notes

Recovery data

h. Operations data (range interference, communications).

3. Data will be recorded and transmitted as follows:

Radar, TIM-18 tracker (where provided) and Doppler

range-tracking precise digital data will be punched on teletype tape

in binary format and transmitted to the 82C for computer analysis

end computations.

Radar and TIM-18 tracker (where provided) data will be

presented at the tracking stations as analog plots for station onthe-spot evaluation of operations.

c. Telemetry data will be recoreded on tape which

will be transmitted to Sunnyvale for analysis for the fastest

available means.

MIER-253

1-5-16

• _r_sararifrVALI_
Waal -orliorbit

Critical telemetered data will be decommutated if

necessary and presented in real time at the tracking stations'.

Space track data - radar data will be transmitted directly

to the STC in real time; optical data will be appropriately reduced

by Space Track and then transmitted.to OTC.

4. • To insure the rapid incorporation of test results in the

planning and conduct of sdbsequent operations it is imperative that

a complete evaluation of each test be accomplished within the time

space occurring between flights. Because of the scope of Discoverer

test operations, this places a most etringent time factor on the tasks

associated with post-test data handling and evaluation. Wary effort

will be made, therefore to streamline the data flow process so that

lag times say be minimised.

B. MA HASDLINGBIOCIDURBS 

General 

Each item of the above types of data will be correlated with

system timing and will be clearly identified as to source, content,

and test number. Other items not listed, but Whidh are pertinent to

test results, will be included in 'written reports. Because of the

moony individual pieces of information latch mat be assembled within

a 'short period of time, every attempt twill be made to deliver each

item of data within a specified time. Deviations dictated by conditions peculiar to an individual flight will be covered in the

detailed test objectives. Other necessary deviationa resulting from

conditions arising during or subsequentto a test will be coordinated

through the OTC. Designated representatives from= and LIOD will

be present at VandmexarggA7B for each flight to collect and handcarry

the required launch data to Santaldwaica and STC.

Thor launch Data 

Douglas (Vandenberg AFB)will be responsible for supplying

booster data ehich'included laundh data, telemetry data, prelaunch

servicing notes and operation data.

3. Discoverer Data 

Lockheed (Vandenberg AFB) mill be responsible for supplying

Discoverer data items as listed above. Delivery of radar and telemetry

tapes gmnerated during orbit flight will be the responsibility of the

tracking station managers utilizing the acesunication network to STC.

mma-253

1-5-17 uONFIDENTIAL
•

I. WM !INDUCTEE 

1. Discoverer Data Reduction 

a. With the exception of data derived from metric optics,

all raw Discoverer test data requiring reduction to usable forms will

be. processed by Imo. Since nearly all quantitative information

derived fray a flight will be of this category, rapid processing of

such data is essential to the timely floe of initrmation. Also,

because of the largo volume and the random order of arrival of many

separate items of data, the procesiing scheme must be both expedient

and highly flexible. To permit an early evaluation of results, the

data reduction process will be accomplished in two parts in the manner

described. below.

"Quick Look" Data. Data reduction required to

support "Quick Look" evaluation activity will be accomplished an a

first priority basis within 24 to 36 hours after receipt of pertinent

radar and telemetry tapes. Nodal "Quick Look" data requirements

will be specified in detail 60 days prior to each flight. Additional

data requirements vhichw be necessary because of flight events Will

be specified after a preliminary review of real time records within

eight hours following the test.

7inai Data. A final, comprehensive compilation of

data as required for detailed subsystem analysis will be completed

within a period. of three to five days after launch.

2. Thor Data Reduction 

The reduction.of booster data will be accomplithedby

Douglas Aircraft Compaq, at Santa Monica. These data will be transmitted to cognizant organizations.

J. SYSTEM EVALUATION

1. A complete operational evaluation of test results will be made.

This evaluation will encompass all weapon system test activities as

they affect the achievement of ultimate progrma goals and objectives.

Major emphasis, however, will be devoted to the timely evaluation of

system flight tests as required to properly redirect the program. The

areas to be covered will include:

a. Over-all system performance in terms of predicted versus

actual results.

WDLES-253

1-5-18
Validity of test plans and conduct in terms of the timely

achievement of test objectives.

Techniques and procedures employed in the conduct of system

test operations.

d. Adequacy and suitability of systems cammanications, ground

support equipment, facilities and logistics.

Detailed follow—through action will be taken on investigation

of problems areas revealed by preliminary evaluation and detailed

analysis. A completely integrated evaluation of over-all system

operation will be performed. Necessary remedial actions affecting the

planning and conduct of the next test will be coordinated with all

organizations concerned and fully Implemented at the earliest possible

date.

Accurate and complete records of program test activity and

results will be maintained. A continuing evaluation of gystea

operations on a flight-to-flight basis will be performed. Operations

concepts, equipment, and procedures will be modified as necessary for

proper program redirection.

WM-253

1-5-19
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"'SECTION III

ELITAPX CONSTRICTION PROGRAM

COAL STATEMENT

The Discoverer program requires facilities to support the following

essential tractions*

s

 test direction, booster and. satellite assembly, and.

checkout ntaintenance and repair; laurch and launch instrumentation . satellite

tracking, control, and telemetry; cepsule recovery; and data interpretation

and dissemination.

All facilities required for the Discoverer program are existing.

MOOD facilities, with exception of the SM-75 Launch Complex at Vandenberg

AFB, were progranmed under the Sentry (118 117L) Development Plan ih the

Fr 1958 Military Constru,ction Progrmn.

3. Rine existing facilities required to support the Discoverer program

and their fractions are as follows:

LOCATION FACILITY DESCRIPTION FUNCTION

Vandenberg AFB Administration Building Program Direction

Launch • Base.

 Bldg. T-11336 1,475 sq ft

Admin. and Storage Bldg.

Bldg. T-11363 1,350 sq it

USD Base Services

Engineering Building DM Base

Bldg. T-11364 2,500 sq ft Engineering

Flight Test Opns. and Test Opns. and

SWAY SWAT

Bldg. T-11362 1,940 sq ft

G.H.E. Bldg.

Bldg. T-113511. 2,950 sq ft

Sub-system "L" Bldg

Bldg. T-11345 2,400 sq ft

G/M Assembly Bldg (Addn

Bldg Nr 9227) 9,000 sq ft

Shop and Administration

Bldg 3200 sq ft

Maintenance and Storage

G.H.E.

Bianedical and

Recovery Package

Maintenance and

checkout

Booster Checkout

GSE Maintenance
FUIETION

USE Base Services

-eeri^t^^

LOCATION

VaWanbw& AFB

Launch Saw

ncnny DISCRIFZION

Receiving and Storage Bldg.

Bldg. T-11344 2,100 sq ft

Interim NAB

Bldg. T-11352 15, sq ft

MA-75 Launch Complex

Thor Launch Pads 4 and 5

associated Blockhouses

and Service Structures

Vandenberg AFB VW Telemetry Receiver Bldg

Txackiog Station 2,300 sq ft

MORT Rader Van

Installation

Agana- Check-out

Launch Thor-boosted

Discoverervebicles

at maximum rate of

two per month

Launch and Orbital

Tree.14ng and Telemetry

Date Reception, trajectory measurements and

calculstions to determine

time to initiate boost.

Nark II Optical. Tracker

Administration 6400 sq ft

and Vim' Telemetry

Receiver Bldg. with 60 foot

Autenna

VARWRT Radar Van

Installation

VW Telemetry Van Installation with Tri-Belix Antenna

Nxisting ACM Composite Bldg.

Orbital 2racking. -

and Telemetry Dabs

Reception

Launch Ascent

Tracking and Telemetry

Data Reception

Final Stage Launch

Tracking and Telemetry

Data Reception

Orbital Tracking and

Telemetry Data

Reception Including

First Pass Acquisition

and Recovery Package

and Impact , Prediction

ICaena Point 

Tracking Station

Oahu, T.N. •

Point Mugu

Tracking Station

N.A.N.T.C.

Pt. Mugu, Calif.

gvt. Joe Z. Mann VBF Telemetry Van InabaLle.-

tion .with Tri-Helix Antenna

Chiniak Tracking VHF Telemetry Van InstallaStatiOn tion with Antenna

—rerlicick, CaP

Alaska

1\1

WDLPR-253

III-2

This document contains information raiding the not add. Slain within the PISOMille of the hPlartala Lows.

TSle IS, U.S.C., Suellen 793 and 794, the tranamisolon of which in ow mamma te an unauthorized mann is prohibited by low.
MIS

LOCATION FACILITY DIBCRIFTION

Hawaiian Control Wing IC of Hale 6,000 sq ft

Center Melted. Bldg.

Rick= APB

FUNCTION

Center for Direction

of Capsule Recovery

Operations.

•

JDLPR-253

within Nog nageoloo of lb. Seplonoge Lows.

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