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DEPARTMENT OF THE AIR FORCE 

WASHINGTON 

OFFICE OF THE SECRETARY 

s%)21 RT DATA ENTE ED 

DATE 

a MICROFICH,ED/ ,, 

.26/67 

JAN 1 G 1967 

MEMORANDUM FOR DR. FLAX 

SUBJECT: Extended Lifetime Support Module 

for MOL 

During the last management meeting, you 

indicated that a paper should be prepared for Dr. 

Foster which would indicate the line of action 

being taken by the MOL Program to provide 

extended lifetime for the automatic version of 

the MOL. Attached is a memo for your signature 

which would provide such information. We have 

discussed the contents with Mr. Kirk and he 

concurs in the approach taken. 

HARRY . EVANS 

Major General, USAF 

Vice Director, MOL Program 

1 Atch 

a/s 

BYE-21016/67 

I I 111111 

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MEMORANDUM FOR DIRECTOR OF DEFENSE RESEARCH & ENGINEERING 

SUBJECT: Extended Lifetime Support Module.for MOL 

You will recall that in our discussions with PSAC which 

have continued since November 1965, and in our comparison 

studies of MOL with wholly unmanned systems, an extended 

lifetime version of the unmanned MOL system was a subject of 

active interest. In the past few months studies have been 

made of a support module which could extend the lifetime of 

an unmanned MOL up to 60 days. These studies have shown that 

such a system extension is entirely feasible within the payload constraint of the TITAN III-M booster. 

Of the several possible arrangements of data reentry 

capsules investigated, our studies resulted in the selection 

of a preferred configuration that will permit the use of up 

to eight capsules, and include a simple automatic film feed, 

cut-off and sealing mechanism. Propellants and reactants 

sufficient for 60 days lifetime can be carried, and it was 

found that the current baseline design for cryogenic tankage 

can be used. The fuel cells themselves will also function 

for the extended lifetime when operated at the lower power 

levels characteristic of the unmanned automatic system. An 

outline sketch of the selected configuration is attached. 

'The extended lifetime analysis arso identified some 

laboratory and mission module components which will require 

some limited extended time testing to determine if a lifetime 

problem exists. Attached hereto is a brief summary of the 

situation in this regard as it now stands. 

BYE-21006/67 

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Our studies indicate that it is desirable and prudent 

in any event to design the baseline system so that a growth 

to a 60-day life can be achieved when desired but to qualify 

the system only for 30 days. Hence; we have concluded that 

the two unmanned flights in the present baseline program 

should be configured for a nominal 30-day lifetime but that 

all volume, weight, and other provisions be made in the design to allow growth to 60 days in the normal course of the 

program; this procedure has been successfully followed in 

other reconnaissance programs of the NRO. This will include 

the use of components which have been validated for, or have 

been modified to permit 60 days of life on orbit. If this 

growth flexibility is built into the unmanned support module 

now, before we are committed to final design, the estimated 

cost of the module would rise from $23 million to $25 million, This seems a worthwhile investment to protect the 

option to exploit the full potential of the unmanned MOL 

configuration at a later time. 

Your concurrence with this approach is requested as 

soon as possible in order that all necessary actions may be 

taken early in the design phase to obviate or minimize any 

necessity for redesign. 

Alexander H. Flax 

Assistant Secretary 

(R&D) 

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Extended Lifetime Support Module '. 

Extended Life Test,Requirements (Preliminary'Estimate) 

o) 1. Laboratory Vehicle (Douglas) 

a. One critical component has been identified. This is the 

liquid hydrogen separator pump in the Electrical Power Subsystem 

Fuel Cell. The problem is simply bearing wearout. This fix is 

mandatory, and consists of a minor bearing redesign and qualification. There is no schedule impact, and cost impact is minimal. 

This fix will be adopted as standard for both 30 and extended 

lifetime versions of MOL. 

b. Only two components have been identified as possible 

marginal items. These are the electronics associated with the 

Electrical Power Subsystem, and the attitude control and Translation Subsystem. An extended life test of both electronics 

packages will be conducted to determine if any weakness exists. 

It is currently estimated that fixes, if required will be minor, 

and no impact on schedule and little on costs is expected. 

c. The humidity control component of the Environmental Control 

and Life Support Subsystem will require additional testing to 

establish its capability to perform for extended times. Control 

of humidity is considered important by Eastman Kodak to proper 

function of some camera equipment components, although the specific 

problems which might arise have not been identified as yet. An 

extended life test of the humidity control will be undertaken to 

determine if weaknesses exist. No major redesign is expected. 

No impact on schedule and little on costs is expected. 

d. Mission Termination Subsystem electronics and propulsion 

components which are normally dormant during the active phase of 

the mission will require testing to determine if they will function 

properly after storage on. orbit for extended times. This is 

considered a minor revalidation and no problems are anticipated. 

2. Mission Module (General Electronic) 

a. No critical items, nor clearly marginal subsystems were 

identified in the extended lifetime studies. There are a number 

of components, however, which :will require extended life testing 

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to reveal weaknesses if they exist. This is particularly true 

of mechanical and electro mechanical components.. At the present 

time, it is expected that no difficulty will be experienced 

with 50% of the items, some minor work may be required on 40%, 

and of the remaining 10%,:considerable work involving minor 

redesign and requalification may be required. At present no 

impact on schedule. and minor impact on cost is'expeCted. The 

components identified Were: 

(1) Rate Gyros 

(2) Star Tracker 

(3) Star Tracker Controller 

(4) Mode Controller 

(5) Tracking Mirror Drive (Drive "A") Electronics 

(6) Viewport Drive (Drive "B") Electronics • 

(7) Drive "A" Pitch Torquer 

(8) Drive "A" Roll Torquer 

(9) Drive "B". Synchro Transmitter 

(10) Drive "B" Synchro Receiver 

(11) Drive "A"Shaft Position Encoder-Roll 

(12) Clamshell Door Drive (Drive "D") Electronics 

(13) Drive "D" Motor 

(14) Drive "D" Motor Controller 

(15) ProgramMer - Sequencer. 

(16) Computer 

(17) . pCM Multicoder 

(18) 256 Channel Multiplexer 

(19) 128 channel Multiplexer 

(20) 5 Volt Power Supply 

(21) Mission Data Adaptor Unit (MDAU) 

(22) Alignment Monitor Electronics 

(23) Power Transfer and Isolution Components 

(24) Power. Controller 

(25) Power Conditioners 

(26) Data Recovery Capsules 

The problem with the Data Recovery Capsule is simply shelf life. 

It is presently qualified for 9 months. However, it is considered 

prudent to re qualify it for a somewhat longer time so that it will 

not run out of time during its progress through system checkout 

launch base activities, and extended stay on orbit. 

3. Camera-Optical-Assembly (Eastman Kodak) 

a. Although the effects of extended life on the Camera Optical 

Assembly are still under study, no critical items have been 

identified. Work will continue to isolate any components which may 

be marginal 

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