Modernize Engine & Flight Testing with Epsilon3
How is it that some organizations have quickly attained repeatable mission success while others always seem to be dealing with valve issues? Our hypothesis: It’s really hard to run effective engine and flight tests with paper procedures. Believe it or not, there are still teams using paper checklists to manage complex tests, just like they did over 50 years ago.
Whether you’re building rockets, jets, planes, or eVTOLs, your mission hinges on the reliability of every component within your vehicle. One missed step during assembly, integration, and testing can lead to quality issues, launch delays, and catastrophic failures. High-stakes operations, like building and launching crewed spacecraft, need to be planned and tracked with extreme accuracy. This is why Epsilon3 was created.
We’re on a mission to modernize the way teams develop and operate advanced systems. Teams using Epsilon3 don’t have to worry about missing steps or running old versions of procedures. The platform offers built-in change tracking and version control, audit and corrective action logs, and integrated telemetry and command data. With conditional logic and dependencies, skipped steps are either prevented or automatically alter the path of the workflow.
Most rocket launch delays and failures were avoidable. Innovative teams like Firefly Aerospace and Virgin Galactic use Epsilon3 to conduct extensive ground testing to verify performance, reliability, and durability under simulated flight conditions. This includes static firing tests, component-level testing, and full-scale engine firing tests, which always involve rigorous valve testing.
To help your team drive mission assurance and success, we’re sharing an example of a full-scale rocket engine test that can be uploaded into and executed with Epsilon3.
Step1: Preparation
Test Stand Setup: Ensure the test stand is configured to securely hold the rocket engine and withstand the forces generated during testing. Complex steps like this often incorporate our parts, tools, and assembly management product.
Instrumentation Installation: Install sensors and data acquisition systems to measure parameters such as thrust, chamber pressure, temperature, and vibration.
Safety Precautions: Conduct safety checks, including verifying emergency shutdown procedures, fire suppression systems, and personnel protective equipment.
Step 2: Ignition System Check
Igniter Functionality: Verify the igniter system's components, including spark plugs or pyrotechnic initiators, to ensure they can reliably ignite the propellants.
Electrical Systems: Check the wiring, power sources, and control circuits to ensure proper connectivity and functionality.
Step 3: Fueling
Propellant Handling: Carefully load the rocket engine with the appropriate propellants, taking precautions to prevent leaks, spills, or accidental ignition.
Propellant Conditioning: Ensure propellants are at the correct temperature and pressure for optimal performance.
Step 4: Ignition
Sequence Initiation: Activate the ignition sequence, open valves to allow propellants to flow into the combustion chamber, and energize the igniter.
Ignition Confirmation: Monitor sensors to confirm successful ignition and combustion initiation. Quickly flag igniter and valve issues using our non-conformance reporting tool.
Step 5: Thrust Build-up
Thrust Monitoring: Measure and monitor thrust levels as they increase, ensuring they align with predicted values and remain within safe operating limits.
Stability Checks: Assess engine stability and performance during thrust build-up, looking for any signs of instability or abnormal behavior.
Step 6: Performance Monitoring
Real-time Data Acquisition: Continuously collect data from sensors monitoring parameters such as thrust, chamber pressure, temperature, and fuel flow rates.
Telemetry Analysis: APIs and integrations enable teams to transmit, analyze, and record data in real-time, reducing the need for manual data entry.
Step 7: Steady-state Operation
Sustained Testing: Operate the engine at a steady-state condition for a predetermined duration, maintaining consistent propellant flow rates and thrust levels.
Stability Assessment: Evaluate the engine's performance over time, ensuring it remains stable and operates within desired parameters. With our test management tool, assess results as conditions, requirements, and variables change.
Step 8: Shutdown
Controlled Shutdown: Execute the shutdown sequence, which may involve gradually reducing propellant flow rates or initiating a rapid cutoff of propellant supply.
Post-Test Safing: Safely depressurize and purge propellant lines to prevent any residual propellants from remaining in the system.
Step 9: Post-Test Analysis
Data Review: Analyze data collected during the test to assess engine performance, identify any anomalies or deviations from expected behavior, and validate simulation models. With software hosted on highly-secure cloud (AWS GovCloud) or on-premise deployments, you can store critical data without compromising security or compliance.
Performance Evaluation: Compare test results against quality, regulatory, and performance requirements to inform corrective actions and future iterations.
When it comes to developing engines and vehicles that carry precious cargo, tracking tests with paper checklists or Excel spreadsheets should be a thing of the past. A dedicated procedure and test management platform results in faster development, improved quality, and safer conditions for your team and customers.
It’s time to modernize engine (and valve) testing with Epsilon3. Book a demo to get started!
About Epsilon3:
We’re a US-based software company on a mission to help teams manage complex operations in highly regulated industries like aerospace, energy, robotics, and manufacturing. Our web-based tools are used by NASA, Blue Origin, Redwire, and AeroVironment to plan and execute mission-critical procedures. The company and platform were purpose-built by engineering leaders from SpaceX, NASA, Northrop, and Google.
