Design optimization of a low-cost three-stage launch vehicle with modular hybrid rocket motors

Abstract

This article investigates the impact of modular propulsion system design on the performance and cost of a three-stage hybrid rocket. Furthermore, it conducts a multi-objective optimization of unit payload cost, take-off mass, and payload mass ratio, considering factors such as the number of motors and layout considerations. The optimization design scheme for the three-stage hybrid rocket is divided into four cases. In the first case, each stage is equipped with a fixed single motor, and each stage is independently optimized without modular design. The second case considers the use of multiple motors in the first and second stages, still without modular design. The third case also involves multiple motors in the first and second stages, but all motors in each stage have identical parameters except for the nozzle expansion ratio, implementing a modular design. In the fourth case, the number and layout of the motor design method are the same as those in the third case, with independent optimization in the third stage using partial modular design. The results indicate that the unit payload cost of the multi-motor non-modular design case can be reduced by 13.12% compared to the single-motor non-modular design case. Within the modular case, the full modular design case is slightly inferior to the partial modular design case. Based on the above data, it can be concluded that the first and second stages of modular rockets offer the best performance and the lowest cost.