Wilson, Brad | Engineering Papers

NASA NTRS2012

OVERFLOW Simulations of Space Shuttle Orbiter Reentry Based on As-Built Geometry

The Space Shuttle Orbiters Discovery and Endeavor have been digitally scanned to obtain outer mold line surfaces. Using these scans, the existing overset computational fluid dynamics (CFD) grid system will be modified by projecting the grid points to the scanned geometry. Simulations will be performed using the OVERFLOW solver and the results compared to previous OVERFLOW results on the theoretical geometry and the aerodynamic databook. The "bent airframe" term will be compared between the aerodynamic databook and the computations over a range of reentry conditions.

Ma, Edward C.↗

NASA NTRS2012

Space Shuttle Orbiter Digital Outer Mold Line Scanning

The Space Shuttle Orbiters Discovery and Endeavor have been digitally scanned to produce post-flight configuration outer mold line surfaces. Very detailed scans of the windward side of these vehicles provide resolution of the detailed tile step and gap geometry, as well as the reinforced carbon carbon nose cap and leading edges. Lower resolution scans of the upper surface provide definition of the crew cabin windows, wing upper surfaces, payload bay doors, orbital maneuvering system pods and the vertical tail. The process for acquisition of these digital scans as well as post-processing of the very large data set will be described.

Campbell, Charles H.↗

NASA NTRS2008

Revitalizing the Space Shuttle's Thermal Protection System with Reverse Engineering and 3D Vision Technology

The Space Shuttle is protected by a Thermal Protection System (TPS) made of tens of thousands of individually shaped heat protection tile. With every flight, tiles are damaged on take-off and return to earth. After each mission, the heat tiles must be fixed or replaced depending on the level of damage. As part of the return to flight mission, the TPS requirements are more stringent, leading to a significant increase in heat tile replacements. The replacement operation requires scanning tile cavities, and in some cases the actual tiles. The 3D scan data is used to reverse engineer each tile into a precise CAD model, which in turn, is exported to a CAM system for the manufacture of the heat protection tile. Scanning is performed while other activities are going on in the shuttle processing facility. Many technicians work simultaneously on the space shuttle structure, which results in structural movements and vibrations. This paper will cover a portable, ultra-fast data acquisition approach used to scan surfaces in this unstable environment.

Wilson, Brad↗

NASA NTRS2008

Revitalizing the Space Shuttle's Thermal Protection System with Reverse Engineering and 3D Vision Technology

The Space Shuttle is protected by a Thermal Protection System (TPS) made of tens of thousands of individually shaped heat protection tile. With every flight, tiles are damaged on take-off and return to earth. After each mission, the heat tiles must be fixed or replaced depending on the level of damage. As part of the return to flight mission, the TPS requirements are more stringent, leading to a significant increase in heat tile replacements. The replacement operation requires scanning tile cavities, and in some cases the actual tiles. The 3D scan data is used to reverse engineer each tile into a precise CAD model, which in turn, is exported to a CAM system for the manufacture of the heat protection tile. Scanning is performed while other activities are going on in the shuttle processing facility. Many technicians work simultaneously on the space shuttle structure, which results in structural movements and vibrations. This paper will cover a portable, ultra-fast data acquisition approach used to scan surfaces in this unstable environment.

Wilson, Brad↗