SPACE SHUTTLE: IMPROVEMENTS

SPACE SHUTTLE: IMPROVEMENTS

During STS-101 Atlantis was the first Shuttle to fly with glass cockpit. Internally the Shuttle remains largely similar to the original design, with the exception of the improved avionics computers. In addition to the computer upgrades, the original vector graphics monochrome cockpit displays were replaced with modern full-colour, flat-panel display screens, similar to contemporary airliners like the Airbus A320. This is called a "glass cockpit". In the Apollo-Soyuz Test Project tradition, programmable calculators are carried as well (originally the HP-41C). With the coming of the ISS, the Orbiter's internal airlocks are being replaced with external docking systems to allow for a greater amount of cargo to be stored on the Shuttle's mid-deck during Station re-supply missions.


Shuttle Orbiter, showing Shuttle main engines. The Space Shuttle Main Engines have had several improvements to enhance reliability and power. This explains phrases such as "Main engines throttling up to 104%." This does not mean the engines are being run over a safe limit. The 100% figure is the original specified power level. During the lengthy development program, Rocketdyne determined the engine was capable of safe reliable operation at 104% of the originally specified thrust. They could have rescaled the output number, saying in essence 104% is now 100%. However this would have required revising much previous documentation and software, so the 104% number was retained. SSME upgrades are denoted as "block numbers", such as block I, block II, and block IIA. The upgrades have improved engine reliability, maintainability and performance. The 109% thrust level was finally reached in flight hardware with the Block II engines in 2001. The normal maximum throttle is 
104%, with 106% and 109% available for abort emergencies.

For STS-1 and STS-2 the external tank was painted white to protect the insulation that covers much of the tank, but improvements and testing showed that it was not required. The 600 lb saved by not painting the tank results in an almost 600 lb increase in payload capability to orbit. Additional weight was saved by removing some of the internal "stringers" in the hydrogen tank that proved unnecessary. The resulting "light-weight external tank" has been used on the vast majority of Shuttle missions. STS-91 saw the first flight of the "super light-weight external tank". This version of the tank is made of the 2195 aluminium-lithium alloy. It weighs 7,500 lb (3.4 t) less than the last run of lightweight tanks. As the Shuttle cannot fly unmanned, each of these improvements has been "tested" on operational flights.

The SRBs (Solid Rocket Boosters) have undergone improvements as well. Notable is the adding of a third O-ring seal to the joints between the segments, which occurred after the Challenger accident.

Several other SRB improvements were planned in order to improve performance and safety, but never came to be. These culminated in the considerably simpler, lower cost, probably safer and better performing Advanced Solid Rocket Booster which was to have entered production in the early to mid-1990s to support the Space Station, but was later cancelled to save money after the expenditure of $2.2 billion. The loss of the ASRB program forced the development of the Super Light-Weight external Tank (SLWT), which provides some of the increased payload capability, while not providing any of the safety improvements. In addition the Air Force developed their own much lighter single-piece SRB design using a filament-wound system, but this too was cancelled.

A cargo-only, unmanned variant of the Shuttle has been variously proposed and rejected since the 1980s. It is called the Shuttle-C and would trade re-usability for cargo capability with large potential savings from reusing technology developed for the Space Shuttle.

On the first four Shuttle missions, astronauts wore full-pressure Launch Entry Suit (LES) during ascent and descent. The pressured helmet was used from STS-5 until the loss of Challenger. The LES was reinstated when Shuttle flights resumed in 1988. The LES ended its service life in late 1995, replacing by the Advanced Crew Escape Suit (ACES).