Engineering topics
Publications and source records attributed to Parmley, R. T..
Supporting element adapts to high or low side loads. Passive Orbital Disconnect Strut (PODS) for cryogenic tank engages an extra-strong member only during peak side or axial loads like those from vibrations, accelerations, and shocks. When side loads are low, support provided by lower-strength, lower-thermal-conductance, passive disconnect.
The objectives of the Passive Orbital Disconnect Struts (PODS) test are to evaluate modal resonance of the PODS-III supports to obtain engineering data required for use of PODS-III on flight systems; determine possible performance improvements in large LO2/LH2 space applications. (1) Modal Vibration Tests. A modal resonance survey is performed on a set of six PODS-III struts assembled in a dewar simulator. The survey conditions simulate both launch and orbital loadings of the struts. The orbital load range spans a full to an empty tank. The frequencies surveyed cover the range consistent with Shuttle qualification requirements and the principal resonant modes of the strut system. (2) Benefit study. The benefit of using PODS-III supports on OTV and Space Station LO sub 2 and LH sub 2 reference tanks was compared to nondisconnect supports. Four LO sub 2 and LH sub 2 tanks were studied under various conditions: (1) holding the launch resonance at 35 Hz and varying the orbit resonance; (2) analyzing both full and emtpy tanks at launch; (3) varying orbit boundary temperaure; (4) varying the number of struts; (5) varying orbit times; and (6) using or not using vapor cooling.
The Space Infrared Telescope Facility (SIRTF) is a long-life cryogenically cooled space-based telescope for infrared astronomy from 2 to 700 micrometers. SIRTF is currently under study by NASA-ARC (Reference AP) and planned for launch in approximately the mid 1990s. SIRTF will operate as a multiuser facility, initially carrying three instruments at the focal plane. It will be cooled to below 2 K by superfluid liquid helium to achieve radiometric sensitivity limited only by the statistical fluctuations in the natural infrared background radiation over most of its spectral range. The lifetime of the mission will be limited by the lifetime of the liquid helium supply, and baseline is currently to be 2 years. The telescope changes required to allow in-space replenishment of the 4,000-L superfluid helium tank was investigated. A preliminary design for the space services equipment was also developed. The impacts of basing the equipment and servicing on the space station were investigated. Space replenishment and changeout of instruments required changes to the telescope design. Preliminary concepts are presented.
A passive orbital disconnect strut (PODS-3) was analyzed structurally and thermally. Development tests on a graphite/epoxy orbit tube and S glass epoxy launch tube provided the needed data to finalize the design. A detailed assembly procedure was prepared. One strut was fabricated. Shorting loads in both the axial and lateral direction (vs. load angle and location) were measured. The strut was taken to design limit loads at both ambient and 78 K (cold end only). One million fatigue cycles were performed at predicted STS loads (half in tension, half in compression) with the cold end at 78 K. The fatigue test was repeated at design limit loads. Six struts were then fabricated and tested as a system. Axial loads, side loads, and simulated asymmetric loads due to temperature gradients around the vacuum shell were applied. Shorting loads were measured for all tests.
The conduction of future space missions will require the long term storage of cryogens in space. Such missions will be performed in connection with the employment of the long life version of the Shuttle Infrared Telescope Facility (SIRTF), the Large Deployable Reflector (LDR), Gravity Probe B (GPB), Orbital Transfer Vehicles (OTVs), and the Space Station. The feasibility of building a long lifetime helium Dewar for space applications has been studied. A feasible concept was to be developed for a Shuttle-launchable 3-yr lifetime Dewar. The developed concept was to be used for the identification of key technology development areas. The desired long lifetime requires the minimization of the parasitic heat loads. It has been found that the majority of the parasitic heat load can be provided by the fiberglass-epoxy tension band supports. A new type of support system, the Passive Orbital Disconnect Strut (PODS), was developed to reduce the considered contribution to the heat load.
The design and test results with a third generation passive orbital disconnect strut (PODS) for space-based cryogenic He dewars are presented. Three pairs of PODS struts support a tank and change lengths in response to gas and temperature changes. A thin wall fiberglass tube is used on the cold disconnect end, which can be operated on the ground or in space. Tests were performed to characterize heat flows across the cold end to a liquid He sink and subsequent vacuum pressure within the He tank. Heat transfer was lower than predicted, suggesting that longer dewar in-orbit lifetimes can be expected with the new PODS.
A test program is undertaken to verify that the lifetime of a shuttle launchable dewar can be increased by using passive orbital disconnect struts (PODS). A detailed design is performed on the cold end (PODS-III) portion of the strut. Structural analysis of the thin-wall fiberglass tube allows selection of the optimum winding angle and tube dimensions. Structural tests on the thin-wall fiberglass tube measure both the tension and compression modulus at ambient and LN2 temperatures, the radial deflection versus side load, and the ultimate compression strength of the tube at LN2 temperature. The thermal expansion of the fiberglass tube plus Invar is also measured down to 78 K. The axial gap at the wedge portion of the stem is set based on these data. The PODS-III test article parts are fabricated and assembled using a detailed assembly procedure. The thermal conductants in the orbital configuration was measured for body temperatures between 5 and 40 K. This temperature range covers the predicted ground hold and orbit temperatures for vapor-cooled supports. The test results are then compared with heat leak values predicted before the test began. Side load, axial compression load, and tension load tests conclude the test program.
A feasible concept for a launchable three year lifetime helium dewar was investigted. Current helium dewar designs were examined to see where the largest potential reductions in parasitic heat loads can be made. The study was also devoted to examining support concepts. The support concept chosen, a passive orbital disconnect strut (PODS), has an orbital support conductance that is lower by more than an order of magnitude over current tension band supports. This lower support conductance cuts the total dewar weight in half for the same three year life time requirements. Effort was also concentrated on efficient wire feed through designs and vapor cooling of the multilayer insulation, supports, wire feed throughs and plumbing penetrations. A single stage helium dewar vs. dual stage dewars with a guard cryogen of nitrogen or neon was examined. The single stage dewar concept was selected. Different support concepts were analyzed from which the PODS support concepts was chosen. A preliminary design of the dewar was thermally and structurally analyzed and laid out including system weights, thermal performance and performance sensitivities.
A new hollow-glass microsphere insulation and a flexible stainless-steel vacuum jacket were demonstrated on a flight-weight cryogenic test tank, 1.17 m in diameter. The weight of the system is three times lighter than the most advanced vacuum-jacketed design demonstrated to date, a free-standing honeycomb hard shell with a multilayer insulation system (for a Space Tug application). Design characteristics of the flexible vacuum jacket are presented along with a model describing the insulation thermal performance as a function of boundary temperatures and emittance, compressive load on the insulation and insulation gas pressure. Test data are compared with model predictions and with prior flat-plate calorimeter test results. Potential applications for this insulation system or a derivative of this system include the cryogenic Space Tug, the Single-Stage-to-Orbit Space Shuttle, LH2 fueled subsonic and hypersonic aircraft, and LNG applications.
A light weight, vacuum jacketed, load bearing cryogenic insulation system was developed and tested on a 1.17-m (46-in.) spherical test tank. The vacuum jacket consists of 0.08 mm (0.003 in.) thick 321 stainless steel formed into a wedge design that allows elastic jacket movements as the tank shrinks (cools) or expands (warms up or is pressurized). Hollow glass spheres, approximately 80 micrometers in diameter with a bulk density of 0.069 g/cc (4.3 lb cubic foot), provide the insulating qualities and one atmosphere load bearing capability required. The design, fabrication, and test effort developed the manufacturing methods and engineering data needed to scale the system to other tank sizes, shapes, and applications. The program demonstrated that thin wall jackets can be formed and welded to maintain the required vacuum level of .013 Pa yet flex elastically for multiple reuses. No significant shifting or breakage of the microspheres occurred after 13 simulated Space Tug flight cycles on the test tank and a hundred 1 atmosphere load cycles in a flat plate calorimeter. The test data were then scaled to the Space Tug LO2 and LH2 tanks, and weight, thermal performance, payload performance, and costs were compared with a helium purged multilayer insulation system.
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Investigation was made to optimize selection of insulation materials for reusable space vehicles which will be repeatedly operated over periods of up to ten years. Results of study are summarized in two reports. Volume I describes tests and significant findings. In Volume II, extensive test data obtained are organized in handbook form.
Twenty candidate multilayer insulation and insulation related materials were subjected to eight conditions that represent possible operational environments. These exposures include ground contaminants, various operational temperatures, space vacuum, space-vented propellants, and tank leakage. The objective of this program was to obtain and evaluate the data from these exposures to provide both a quantitative and qualitative description of the degradation to certain physical and thermal properties, and from this, to obtain a better understanding of the environmental effects on the insulation performance.
For Abstract See
Development and characteristics of protective coatings for spacecraft
Shingle attachment of multilayer insulation to cryogenic flight tanks