How NASA Brought the F-1 Rocket Engine Back To Life
First time accepted submitter Martin S. writes "How NASA Engineers have reverse engineered the F1 engine of a Saturn V launcher, because: 'every scrap of documentation produced during Project Apollo, including the design documents for the Saturn V and the F-1 engines, remains on file. If re-creating the F-1 engine were simply a matter of cribbing from some 1960s blueprints, NASA would have already done so.
A typical design document for something like the F-1, though, was produced under intense deadline pressure and lacked even the barest forms of computerized design aids. Such a document simply cannot tell the entire story of the hardware. Each F-1 engine was uniquely built by hand, and each has its own undocumented quirks. In addition, the design process used in the 1960s was necessarily iterative: engineers would design a component, fabricate it, test it, and see how it performed. Then they would modify the design, build the new version, and test it again. This would continue until the design was "good enough."'
Bernie Eccelstone is suing for trademark infringement
the design process used in the 1960s was necessarily iterative: engineers would design a component, fabricate it, test it, and see how it performed. Then they would modify the design, build the new version, and test it again. This would continue until the design was "good enough."'
take note modern IT managers - this is agile, not that bastardised process-heavy "agile" scrum-style crap you do today.
They had no computers, or they invented them?
It's neither, actually. But by 1963 manufacturing, at least for the money-means-nothing military, was already computerized.
http://www.youtube.com/watch?feature=endscreen&v=_1g1b_EeVHw&NR=1
Why do you think it's called "numerically controlled" and not "digital"? It's because the whole concept is so old that the wording has had time to become obsolete.
So, kind of like how slashdot is developed?
Sounds like my engineers in Kerbal Space Program. But instead of having massive failures where the whole rocket explodes, they have more controlled ones.
I mentioned this in a comment last week. Manned spaceflight in the USA is essentially a matter of history, not something we know how to do today. If we wanted (for whatever reason) to go back to the moon, we'd bascially have to start over from scratch. It would probably take as at least as long as the original Apollo program, and cost far more.
After the fall of the Roman empire, knowledge of concrete was lost, and for about 500 years Europeans were walking around Roman buildings and upon Roman roads that they had no idea how to recreate. Right now all our Apollo engineers are dead or dying, and the Astronauts will soon follow suit. Soon there will be no living human who has set foot on another world. Then we will know just how those Medieval Europeans felt when we go look at our old Apollo relics in the museums.
Yes, if one is doing a one off project, or a prototype that will then be given to someone else to redesign, the perhaps this is the a good method.
Every mid to large sized IT shop I've ever seen or worked in (dozens) has basically been a "one-off project" when viewed as a whole. Yes sure, every one is basically built out of off-the-shelf hardware and OSes, but there is so much customization and scripting, customized apps and databases and communication software, and other various "glue" bits holding these microcosms all together, but after you examine the innards of any decent sized IT shop that's been running a while, the place as a whole is actually a giant hodge-podge Rube Goldberg contraption that has evolved and taken final shape over time and iterative development.
We've not building Henry Ford assembly line Model Ts here.
Just because we don't understand how the F-1 engines were built, doesn't mean we do not understand how rocket engines are built. Why is NASA trying to reverse engineer an engine that was designed without modern computer aided design and without access to modern materials? Do they really think those engines were perfect and you can't possibly do any better? No, they seem to think they will "save money" by using the old design. How can it be easier to try and reverse engineer all the design requirements from an existing engine than to create a new design where you know the design requirements? This philosophy is why big aerospace is having such massive problems. This is why SpaceX has delivered supplies to the ISS twice, while the Antares rocket (Orbital Science Corporation) is still sitting on the ground. SpaceX designed their rockets from scratch, while OSC is using rockets designed in the 1960s.
It is not yet possible for a machine to repair itself - once it is damaged, it is permanent, nothing to fix it.
A man on site could repair that machine, even if it took wire and duct tape - it would work long enough to get a job done.
A machine (at least ALL current machines) have very poor eyesight. A person looking at a scene can identify events that machines overlook. They get curious and make a closer look. A machine that has to be scheduled to look takes so long to get scheduled that the closer look itself is overlooked.
The biggest engines we could buy for our model rockets was the D. This F is awesome!
And it's just the F1 !
(-1: Post disagrees with my already-settled worldview) is not a valid mod option.
A typical design document for something like the F-1, though, was produced under intense deadline pressure and lacked even the barest forms of computerized design aids.
Thank goodness for that. People still know how to read paper drawings. If it was computerized, we might be able to read the media if it survived (1/2" mag tape or punch cards) but would probably have to spend a lot of time reverse engineering obsolete CAD formats.
We constantly test, and call it good enough. The difference is the fighter is going to cost more than the Saturn missions...go figure.
This reads to me like We have no idea how these rockets work, his secrets lost in a sea of details. The result a non repeteable prototype. We cant build another one wihout reinventing it.
These are the types of Articles I still come to Slashdot for ... and for the comments, which have (sadly) diminished in quantity in the last decade. Amazing engineering work, amazing science.
We emerge from our mother's womb an unformatted diskette; our culture formats us. - Douglas Coupland
I have the biggest space boner right now.
They had CAD applications, just not what you think as CAD. Anyways, this is interesting, because when do you think CAD applications started? Did the whole thing just pop into existence fully formed, or were there intermediary steps? Just on the electronics side, look at something like SPICE. It didn't pop into existence with a GUI on a personal computer, it started as a punch-card reading batch application on a mainframe.
SPICE dates to 1972. The Saturn V had been designed, built, flown, and out of production for years by the time SPICE was released to the public.
To be fair, SPICE derived from CANCER ("Computer Analysis of Nonlinear Circuits, Excluding Radiation"). But that was also not released to the public ready until the early 70s (the paper describing it was dated 1971: http://ieeexplore.ieee.org/xpls/abs_all.jsp?arnumber=1050166 )
Boom, computer aided design.
"Boom," just in time to be ten years too late to be used in the Apollo program.
http://www.geoffreylandis.com
Hello,
Some people are claiming that all spaceflight knowledge in this country has been lost and it would cost far more (in constant dollars?) to re-do what was done in the 60's to get us to the moon. I'm not so sure.
I'm working in an engineering field (not rocket science) which was dominated by experimentation/prototyping when it was "hot" (WWII and shortly thereafter). Giant teams of people (100s or more) would be doing what our very small team is today (3-ish).
Granted, we have their shoulders to stand on, but instead of doing a WHOLE LOT of prototypes, we run supercomputer simulations and "try out" thousands of designs. And when we build them, they work--the first time.
I would say we re-do (sort of, actually we're pushing today's technological boundaries) the equivalent of what our fathers and grandfathers had done, faster, cheaper, better, and with stupider, less-skilled people (I'm including myself) --because we have better tools to extend our minds and bodies with today.
So I am not so sure that re-engineering the Apollo program would cost anything like the original development program. I think it would depend on what kind of modeling tools and other tech developments are available now that didn't exist then.
What's more, we're currently executing what I would call an "archaeology" project, reviving a 40-year-old design. The existing documentation is lacking, but it's still helping us a lot--we'll probably get this thing built for 1/10th the cost "back when" thanks to what our ancestors have left us and thanks to the tools we have today. And we might even build it better than they could ever have done, thanks to being able to use supercomputers to search for an optimal design.... But that remains to be seen.
--PeterM
The Saturn V was designed with paper and slide rules, and very little computer work.
As far as circuit simulation goes, ECAP is probably the first full circuit simulator. I have a copy of the manual for the 1620 version, but it's dated 1970, but there are earlier versions. All written in FORTRAN. I'll bet that almost no computer simulation was done for the electronics on the Saturn V.
For thermal and mechanical FEM analysis, NASTRAN started in 1964 and was delivered in 1968 Not used for Apollo, but used for Shuttle.
Drafting wise, Sutherland's Sketchpad was in 1963, and was pretty much the first "drawing" tool on a computer, and it used custom hardware, and was hardly usable for actual drafting.There were some specialized tools for splines and such in the car industry, but "real" drafting on a computer probably didn't exist until the 70s. (Drafting or Technical Drawing was still a course you took in high school in the mid-70s.)
We constantly test, and call it good enough. The difference is the fighter is going to cost more than the Saturn missions...go figure.
Well, there is no doubt a ton of waste in the fighter programs, but do consider that the Saturn V did not have to deal with people trying to shoot it down, only had a run of a dozen or two units, and each unit only had to work one time on a single day, only spending a few days outdoors. That means that you could have a complex series of tests/checks/etc that all take place up until launch which are good for only that one launch. You can't exactly design an F-35 so that you need to reassemble the thing from components before every mission, or dictate that if it is a rainy day you'll just postpone the mission until the next day, or that the fighter would throttle up the engines exactly once, slowly reduce thrust as fuel is burned off, shut them off, and never use them again.
, and if you pass a certification test, commercial motors up to an O-8000 are available if you have the cash:
http://www.pro38.com/products/pro150/motor.php
Model rocketry has come a LONG way since cardboard Estes rockets in the schoolyard....
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They needed them smaller, but banks and businesses needed them cheaper and more reliable.
Correct. NASA was the driver for small computers, where "small" meant "smaller than a room." Pretty much all other applications-- such as the banks and businesses you mention-- used timeshare on big mainframes. Or, for the early 60s, sent the punch-cards to the mainframe to be entered.
By the way, in 1963 banks mostly didn't use computers. You youngsters are too young to remember when a bank "passbook account" meant a physical object that the teller wrote in by hand.
How can NASA be a "driver" for ICs when they were using generic commercial ICs????
They paid the companies to develop those products in the first place, because they didn't exist until the NASA contracts to develop them. The IC was developed with Air Force and NASA funding, because at the time, those were the two customers for whom integrated circuits were an enabling technology.
The comment you're responding to was about computer design tools--CAD--not about numerically-controlled milling machines."
They designed the parts on computers.
Wrong.
They fabricated the parts as part of a computer-driven process.
Wrong.
Look, learn something about 1963 before posting so confidently about how engineering was done with computers back in the early 60s, OK? Do you even know what a slide-rule was???
http://www.geoffreylandis.com
Random Access Method of Accounting and Control
IN 1956.
First of all, we need to define what I mean by designing parts on a computer. Were they sitting in front of personal computers with a mouse, color graphics, stereo sound and brazilian tranny porn? No. But are you claiming they never ever used computers to run numerical simulations for critical parts?
You ever hear of Messier Dowty? This is a company in Quebec that built the landing gear for the LEM. Guess what they used to help design them? Early computers and software at the Polytechnique.
If you ask a computer to solve an equation that's needed to help guide the design of a part, what is that but computer aided design? So sorry it was all on punch cards. Still a computer.
SPICE was a combination of earlier programs...
Right. Specifically, what I said was "SPICE derived from CANCER ("Computer Analysis of Nonlinear Circuits, Excluding Radiation")."
So, you think they didn't use computers to solve numerical problems in 60s? Problems related to design? Is this what you are claiming?
The article said that the F-1 engines were not designed with computerized design aids. That is correct. CAD was just being developed-- in fact, it used to be called "Computer Assisted Drafting", long before it became a design tool-- and was not being used at MSFC back then.
http://www.cadbuilt.com/cad-drafting.html
I don't think you have much of a memory of what engineering was like in the 1960s. You might try some of these:
http://history.nasa.gov/monograph45.pdf
http://history.msfc.nasa.gov/saturn_apollo/documents/F-1_Engine.pdf
http://www.geoffreylandis.com
F1 is a engineering marvel but shame it's only used for three minutes then dumped into the ocean. Think of all the design, craftsman machining, and all the horrible bureaucracy of documentation from parts selection, materials testing, assembly checks, auditing of special tools (and each tool has tons of paperwork). Armies of technicians and engineers working on just one engine. And many are built, and very $$$expensive$$$. Imagine if booster can be recovered, engines reused, the only thing lost is the propellent. But then Saturn V had a purpose to beat the Reds to the moon, performance at any cost. It may be very expensive but damned the costs if the Soviets beat us to the moon, plant the hammer and sickle flag that will enslave the world in communism. Meanwhile back in the 21st century, everyone is arguing about SLS. Like the Soviets that failed to reach the moon mainly because they never really committed to landing a cosmonaut on the moon. Many argued about N1, politicos never gave it full funding, many engineers argued among themselves. Substitute SLS for N1... well going OT. Then there is SpaceX knowing value in recovering launch vehicles to save those engines. And the Soyuz marches on!
mfwright@batnet.com
Meanwhile, Space-X is building the Falcon Heavy, with twice the payload of the Space Shuttle. The Falcon Heavy is three Falcon-9s. The Falcon-9, which is in current production and has been launched successfully several times, uses 9 Merlin engines. The Merlin engine is in current production, and about 400 a year are being manufactured. The first Falcon Heavy launch is scheduled for this year. For an actual commercial customer.
So why is NASA trying to build a big booster again?
Don't be brainwashed by all this "process" crap. These days you have to talk to guys in their 60's and 70's to get the full oral history, but they wistfully recall days when the emphasis was on getting things done and making them work, rather than mindlessly following "process".
All that "process crap" is exactly how any successful engineering project is done. The space program in the 60's and 70's was no exception. Do some reading about the actual engineering that went on and you'll quickly realize it was ALL about developing working processes. A process is nothing more than a set of procedures used to accomplish a task. If the task has to be communicated to someone else or cannot be overlooked or is just plain complicated, documentation becomes a vital aspect of the process. You can't build something as complicated as a space ship without a huge amount of extremely robust processes and accompanying documenation. Developing effective production processes isn't mindless busywork - it is among the most challenging and important things we do. The best manufacturing companies spend a tremendous amount of resources on process development because without them they would be unable to function.
If you want to ensure that a rocket blows up, by all means ignore developing processes and don't worry about documenting or communicating the procedures used. Just be a cowboy and "get it done". When you have no way to discover what went wrong, who was responsible, when you were supposed to do it or how to do it again you might begin to understand why process is important. My company makes wire harnesses and we've made products that have gone into space. For even the simplest cable with a crimped terminal on one end we typically have about 15+ pages (and often much more) of assembly instructions, QA instructions, machine setup instructions, QA logs, shipping and packaging instructions, manufacturing orders (how many to build and when to build them), bills of material, training documentation, defect logs, packing slips, and invoices. And every bit of that documentation is genuinely important. Without robust processes in place it would be complete chaos to try to make even the most basic products, never mind something as complicated as a F1 engine. All that "process crap" lets us build a high quality product (repeatedly if needed), diagnose and correct any problems that may arise, and make sure everyone knows what they are supposed to do and when they are supposed to do it.
A decade ago, I would have been delighted for a modernized Saturn V, now I think, how can they possibly do cheaper than SpaceX?
SpaceX started a decade ago, with Elon Musk's money, and veteran TRW rocket engineer Tom Mueller. They then recruited an elite team of experienced rocket engineers. They designed the rocket from scratch for manufacturability, and had the benefit of four decades of rocket engine history, and the low cost fastrack rocket engine. SpaceX benefits from the hundreds of engineers at Tesla Motors, with modern, robot heavy, car manufacturing expertise.
At the end of the day, the manned space program is pork driven. Orrin Hatch will not let the liquid boosters replace solid, or the Falcon super heavy see the light of day.
Sure they had computers, on the ship, on the ground and all, but not in the engineering department. Engineers where able to make technical drawings and hand that of to workers building the actual thing. Oh yea and they assisted and oversaw the work done, to correct any misunderstandings. It worked, why add computers.
Why add computers? Because it makes the lives of us engineers who do what you are describing (I am one) VASTLY easier. I've worked on a drafting table and I know how to use a slide rule. I've designed products and overseen their production. While it can be done without computers I don't really relish the thought of going back to the days without them. People who pine for the "good old days" when we didn't have computers to help with the work almost invariably never had to actually do real engineering without them. Trust me, it sucked.
Do you have any idea how much labor is involved in updating a set of work instructions and ensuring only the most recent version is distributed? Have you ever done a complicated product drawing on paper and then had to do it over again because of a revision? It's possible to do these things without computers but I can assure you from first hand experience that you don't really want to. It's much easier to edit a CAD model of a part and then print out the new revision. It's is FAR easier to use a versioning system to keep documentation up to date and distributed to the right places. We don't use computers just because we can. We do it because it makes us far more effective and faster at our jobs.
Yes, books written in 2006 and not specifically about computer use in the 1960s are the best you can do? Weak sauce, man.
when you really have to you can make miracles (and cut corners with a calculated risk), look at all the airplanes, tanks etc. that was build during the ~5 years WWII
today it would be hard to just design, let alone build and test a single airplane in that time frame
the spacerace was a kind of war, jsut on skills instead of kills
They used freakin slide rules back then dude. What passed for computers in the early 60s was shit. Get over it. Go do some CAD/CAM on your TI calculator - it is probably an order of magnitude more powerful.
By the way, in 1963 banks mostly didn't use computers. You youngsters are too young to remember when a bank "passbook account" meant a physical object that the teller wrote in by hand.
I had one of those when I was little in the 80s. At that time the teller didn't write in it by hand but it had printed entries from the dot matrix printer the teller would put it into. I had forgotten about those accounts until you mentioned it.
Time to offend someone
The design was made, in the 1960's by blueprint, and each change would be made by another blueprint. And the copies sent to the fabrication/shop floor for use, and pitched if no good, but pitched from the shop floor. In one of my earlier jobs I was in tool and die for a major producer. We had only the latest iteration of a design on the floor, so as to not confuse the process for creating the tools to make the parts to be installed on the next greatest.... amazing how we had better designs then, then now.....heehhh
"Russia did it better on less than one hundredth of the budget,"
Russia never landed a human on the moon.
You were mistaken. Which is odd, since memory shouldn't be a problem for you
Go fuck off. You haven't shown a single reference to indicate the level of computer design done in the 60s. So all things considered, the books he mentioned are far better than anything you've suggested.
Just because clerks and people still had paper bank books doesn't mean computers weren't used to crunch numbers... I had paper bank books in the 1980s, does that mean banks had no computers in the '80s
You seem to keep running what everyone says through some filter that adds hyperbole, and then freak out and respond to something more absolute than what was said. There is a huge difference between someone saying they mostly didn't use computers for day to day operations, and you interpreting that to mean they didn't have computers.
If you ask a computer to solve an equation that's needed to help guide the design of a part, what is that but computer aided design? So sorry it was all on punch cards. Still a computer.
It is a huge stretch to call that computer aided design. You are talking about a big calculator.
It's much easier to edit a CAD model of a part and then print out the new revision. It's is FAR easier to use a versioning system to keep documentation up to date and distributed to the right places. We don't use computers just because we can. We do it because it makes us far more effective and faster at our jobs.
And how relevant is that to the 1960s? Either way you would end up with a team working for you, whether inputting things into the computer or updating and managing drawings... just which team would be bigger, slower, and more expensive back in the time period being referenced in this discussion?
Since you seem to have been around for a time before computers were used for such work, what year did you switch over from the manual process to computer based processes?
Screw the F-1. They should resurrect the M-1; that thing was AWESOME.
Aerojet's M-1 was the largest and most powerful liquid hydrogen-fueled rocket engine to be designed and component tested. The M-1 offered a baseline thrust of 6.67 million N (1.5 million lbf) and 8 million N (1.8 million lbf) as its immediate growth target. If built, the M-1 would be larger and more efficient than the famed F-1 that powered the first stage of the Saturn V rocket to the moon.
Yes, books written in 2006 and not specifically about computer use in the 1960s are the best you can do? Weak sauce, man.
These are about the Saturn F-1 engine development, not about computers. There are other books, including some memoirs. The ones I linked have the advantage of being easily available on the web.
I wasn't trying to claim that computers didn't exist in 1960!
http://www.geoffreylandis.com
Oh true, but the F-35 was supposed to be the cheaper cousin to the F-22. Now the F-22 is cheaper than the F-35 per plane when total longevity is factored.
What's wrong with that...
We might as well, restart the F-22 program. Cancel 90% of the F-35, and simply create the VTOL Marine/Carrier version of the F-35 for the Marines. And cancel all others.
The F-35 is also needed for the Navy. I agree you could ditch 1/3 versions from a US perspective, but would that really save much money? The Air Force variant of the plane is likely the cheapest anyway (though why they can't just use the carrier version I do not know).
I am pretty impressed that they managed to drive the cost of the "cheap" plane above that of the "expensive" one...