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At least 181 records · Page 10

Using Hardware-In-The-Loop Methodology to Develop Test Systems

Hardware in the Loop (HIL) testing methodologies have become widespread in industry. Typically, they focus on developing control algorithms for systems such as autonomous vehicles or aircraft. An oft overlooked aspect of product development is the design and fabrication of a test system for validating that the product meets requirements. Abstractly, a test system differs little from a control system—testers provide signals to the unit, monitor feedback, and base decisions on the results. While the time scales may differ, the functionalities are conceptually similar. Viewed in this light, it becomes natural to extend HIL approaches to tester development. By replacing a physical unit with a proxy model deployed to a real-time or pseudo real-time target, test systems can be developed in parallel with the design and fabrication of a first production unit. This saves considerable time in the life cycle from conceptual design to realized product. This manuscript demonstrates the process flow using a capacitive discharge unit as an exemplar.

42 ENGINEERING↗

Operational and Mission Highlights A Monthly Summary of Top Achievements April 2022

When the Laboratory’s Detonator Production team originally completed manufacturing two ALT939 DEV#1 functional cables — the first development units produced in this lot, team members quickly hit an obstacle when electrical testing for these cables failed. Team members sent the cables out for further testing, which revealed the root cause of failure involved the cables’ connectors. Although a challenging issue to resolve, the team worked together and solved the issue ahead of a stipulated deadline, with the cables completed and shipped to support system tests. The team responsible for this challenging work included members from Detonator Production, Nondestructive Testing & Evaluation, and collaborators from Sandia National Laboratories.

42 ENGINEERING↗

Vapor Compression Distillation Subsystem (VCDS) component enhancement, testing and expert fault diagnostics development, volume 1

Vapor compression distillation technology for phase change recovery of potable water from wastewater has evolved as a technically mature approach for use aboard the Space Station. A program to parametrically test an advanced preprototype Vapor Compression Distillation Subsystem (VCDS) was completed during 1985 and 1986. In parallel with parametric testing, a hardware improvement program was initiated to test the feasibility of incorporating several key improvements into the advanced preprototype VCDS following initial parametric tests. Specific areas of improvement included long-life, self-lubricated bearings, a lightweight, highly-efficient compressor, and a long-life magnetic drive. With the exception of the self-lubricated bearings, these improvements are incorporated. The advanced preprototype VCDS was designed to reclaim 95 percent of the available wastewater at a nominal water recovery rate of 1.36 kg/h achieved at a solids concentration of 2.3 percent and 308 K condenser temperature. While this performance was maintained for the initial testing, a 300 percent improvement in water production rate with a corresponding lower specific energy was achieved following incorporation of the improvements. Testing involved the characterization of key VCDS performance factors as a function of recycle loop solids concentration, distillation unit temperature and fluids pump speed. The objective of this effort was to expand the VCDS data base to enable defining optimum performance characteristics for flight hardware development.

Kovach, L. S.↗

Brassboard Astrometric Beam Combiner (ABC) Development for the Space Interferometry Mission (SIM)

The Astrometric Beam Combiner (ABC) is a critical element of the Space Interferometry Mission (SIM) that performs three key functions: coherently combine starlight from two siderostats; individually detect starlight for angle tracking; and disperse and detect the interferometric fringes. In addition, the ABC contains: a stimulus, cornercubes and shutters for in-orbit calibration; several tip/tilt mirror mechanisms for in-orbit alignment; and internal metrology beam launcher for pathlength monitoring. The detailed design of the brassboard ABC (which has the form, fit and function of the flight unit) is complete, procurement of long-lead items is underway, and assembly and testing is expected to be completed in Spring 2009. In this paper, we present the key requirements for the ABC, details of the completed optical and mechanical design as well as plans for assembly and alignment.

PlanetQuest↗

Improved Predictive Tools for Structural Properties of Metal–Organic Frameworks

The accurate determination of structural parameters is necessary to understand the electronic and magnetic properties of metal–organic frameworks (MOFs) and is a first step toward accurate calculations of electronic structure and function for separations and catalysis. Theoretical structural determination of metal-organic frameworks is particularly challenging because they involve ionic, covalent, and noncovalent interactions, which must be treated in a balanced fashion. Here, we apply a diverse group of local exchange-correlation functionals (PBE, PBEsol, PBE-D2, PBE-D3, vdW-DF2, SOGGA, MN15-L, revM06-L, SCAN, and revTPSS) to a broad test set of MOFs to seek the most accurate functionals to study various structural aspects of porous solids, in particular to study lattice constants, unit cell volume, two types of pore size characteristics, bond lengths, bond angles, and torsional angles). The recently developed meta functionals revM06-L and SCAN, without adding any molecular mechanics terms, are able to predict more accurate structures than previously recommended functionals, both those without molecular mechanics terms (PBE, PBEsol, vdW-DF2, and revTPSS) and those with them (PBE-D2 and PBE-D3). To provide a broader test, these two functionals are also tested for lattice constants and band gaps of unary, binary, and ternary semiconductors.

36 MATERIALS SCIENCE↗

Hypersonic research engine project. Phase 2: Aerothermodynamic Integration Model (AIM) data reduction computer program, data item no. 54.16

The data reduction program used to analyze the performance of the Aerothermodynamic Integration Model is described. Routines to acquire, calibrate, and interpolate the test data, to calculate the axial components of the pressure area integrals and the skin function coefficients, and to report the raw data in engineering units are included along with routines to calculate flow conditions in the wind tunnel, inlet, combustor, and nozzle, and the overall engine performance. Various subroutines were modified and used to obtain species concentrations and transport properties in chemical equilibrium at each of the internal and external engine stations. It is recommended that future test plans include the configuration, calibration, and channel assignment data on a magnetic tape generated at the test site immediately before or after a test, and that the data reduction program be designed to operate in a batch environment.

Gaede, A. E.↗

SMART: The Future of Spaceflight Avionics

A novel avionics approach is necessary to meet the future needs of low cost space and lunar missions that require low mass and low power electronics. The current state of the art for avionics systems are centralized electronic units that perform the required spacecraft functions. These electronic units are usually custom-designed for each application and the approach compels avionics designers to have in-depth system knowledge before design can commence. The overall design, development, test and evaluation (DDT&E) cycle for this conventional approach requires long delivery times for space flight electronics and is very expensive. The Small Multi-purpose Advanced Reconfigurable Technology (SMART) concept is currently being developed to overcome the limitations of traditional avionics design. The SMART concept is based upon two multi-functional modules that can be reconfigured to drive and sense a variety of mechanical and electrical components. The SMART units are key to a distributed avionics architecture whereby the modules are located close to or right at the desired application point. The drive module, SMART-D, receives commands from the main computer and controls the spacecraft mechanisms and devices with localized feedback. The sensor module, SMART-S, is used to sense the environmental sensors and offload local limit checking from the main computer. There are numerous benefits that are realized by implementing the SMART system. Localized sensor signal conditioning electronics reduces signal loss and overall wiring mass. Localized drive electronics increase control bandwidth and minimize time lags for critical functions. These benefits in-turn reduce the main processor overhead functions. Since SMART units are standard flight qualified units, DDT&E is reduced and system design can commence much earlier in the design cycle. Increased production scale lowers individual piece part cost and using standard modules also reduces non-recurring costs. The benefit list continues, but the overall message is already evident: the SMART concept is an evolution in spacecraft avionics. SMART devices have the potential to change the design paradigm for future satellites, spacecraft and even commercial applications.

Alhorn, Dean C.↗

Full-Scale Tests of NACA Cowlings

A comprehensive investigation has been carried on with full-scale models in the NACA 20-foot wind tunnel, the general purpose of which is to furnish information in regard to the physical functioning of the composite propeller-nacelle unit under all conditions of take-off, taxiing, and normal flight. This report deals exclusively with the cowling characteristics under condition of normal flight and includes the results of tests of numerous combinations of more than a dozen nose cowlings, about a dozen skirts, two propellers, two sizes of nacelle, as well as various types of spinners and other devices.

Theodorsen, Theodore↗

Escort - A data acquisition and display system to support research testing

A combination of a central minicomputer and test-site microcomputers has been adopted to provide on-line data acquisition and display service for a large number of different research programs. By integrating the data acquisition and recording functions in the minicomputer/microcomputer system, rapidly updated displays of selected data in terms of engineering units may be obtained. The system described here is primarily designed for steady-state test conditions, but may also provide data on slow transients associated with changing experimental conditions. Application of the system to full-scale jet engine tests, ion thruster assessments and anechoic chamber analyses are mentioned.

Miller, R. L.↗

Evolution of the IBDM Structural Latch Development into a Generic Simplified Design

This paper presents the evolution in the development of the structural latch for the International Berthing Docking Mechanism (IBDM, see Figure 1). It reports on the lessons learned since completion of the test program on the engineering development unit of the first generation latching system in 2007. The initial latch design has been through a second generation concept in 2008, and now evolved into a third generation of this mechanism. Functional and structural testing on the latest latch hardware has recently been completed with good results. The IBDM latching system will provide the structural connection between two mated space vehicles after berthing or docking. The mechanism guarantees that the interface seals become compressed to form a leak-tight pressure system that creates a passageway for the astronauts.

DeVriendt, K.↗

Space Suit Portable Life Support System (PLSS) 2.0 Pre-Installation Acceptance (PIA) Testing

Following successful completion of the space suit Portable Life Support System (PLSS) 1.0 development and testing in 2011, the second system-level prototype, PLSS 2.0, was developed in 2012 to continue the maturation of the advanced PLSS design which is intended to reduce consumables, improve reliability and robustness, and incorporate additional sensing and functional capabilities over the current Space Shuttle/International Space Station Extravehicular Mobility Unit (EMU) PLSS. PLSS 2.0 represents the first attempt at a packaged design comprising first generation or later component prototypes and medium fidelity interfaces within a flight-like representative volume. Pre-Installation Acceptance (PIA) is carryover terminology from the Space Shuttle Program referring to the series of test sequences used to verify functionality of the EMU PLSS prior to installation into the Space Shuttle airlock for launch. As applied to the PLSS 2.0 development and testing effort, PIA testing designated the series of 27 independent test sequences devised to verify component and subsystem functionality, perform in situ instrument calibrations, generate mapping data to define set-points for control algorithms, evaluate hardware performance against advanced PLSS design requirements, and provide quantitative and qualitative feedback on evolving design requirements and performance specifications. PLSS 2.0 PIA testing was carried out from 3/20/13 - 3/15/14 using a variety of test configurations to perform test sequences that ranged from stand-alone component testing to system-level testing, with evaluations becoming increasingly integrated as the test series progressed. Each of the 27 test sequences was vetted independently, with verification of basic functionality required before completion. Because PLSS 2.0 design requirements were evolving concurrently with PLSS 2.0 PIA testing, the requirements were used as guidelines to assess performance during the tests; after the completion of PIA testing, test data served to improve the fidelity and maturity of design requirements as well as plans for future advanced PLSS functional testing.

Watts, Carly↗

A Recommended New Approach on Motorization Ratio Calculations of Stepper Motors

Stepper motors are widely used on most spacecraft mechanisms requiring repeatable and reliable performance. The unique detent torque characteristics of these type of motors makes them behave differently when subjected to low duty cycle excitations where the applied driving pulses are only energized for a fraction of the pulse duration. This phenomenon is even more pronounced in discrete permanent magnet stepper motors used in the space industry. While the inherent high detent properties of discrete permanent magnets provide desirable unpowered holding performance characteristics, it results in unique behavior especially in low duty cycles. Notably, the running torque reduces quickly to the unpowered holding torque when the duty cycle is reduced. The space industry's accepted methodology of calculating the Motorization Ratio (or Torque Margin) is more applicable to systems where the power is continuously applied to the motor coils like brushless DC motors where the cogging torques are low enough not to affect the linear performance of the motors as a function of applied current. This paper summarizes the theoretical and experimental studies performed on a number of space qualified motors under different pulse rates and duty cycles. It is the intention of this paper to introduce a new approach to calculate the Motorization Ratios for discrete permanent magnet steppers under all full and partial duty cycle regimes. The recommended approach defines two distinct relationships to calculate the Motorization Ratio for 100 percent duty cycle and partial duty cycle, when the motor detent (unpowered holding torque) is the main contributor to holding position. These two computations reflect accurately the stepper motor physical behavior as a function of the command phase (ON versus OFF times of the pulses), pointing out how the torque contributors combine. Important points highlighted under this study are the torque margin computations, in particular for well characterized mechanisms. The rationale at CDR level versus TRR/TRB level will be discussed, aiming at avoiding too much conservatism for units that have extensive test and in flight heritage. A critical topic is related to the magnetic losses and how to sort out such phenomena as a function of the motor type being used. For instance, detent torque is a major contributor that has no reason to evolve during life and is not an uncontrolled torque loss.

Nalbandian, Ruben↗

Development Of 12 Kw Hall Thrusters for Nasa Lunar Gateway Power And Propulsion Element

NASA is embarking on a new and exciting era of human exploration to the Moon and its vicinity. As part of the Artemis program, NASA is developing the lunar Gateway, an orbiting platform in Near Rectilinear Halo Orbit (NRHO) about the Moon. The first two elements of the Gateway will be launched in 2024 and will be transferred from a high Earth orbit to the NRHO via the use of Solar Electric Propulsion (SEP). The SEP system is located on the Power and Propulsion Element (PPE) which will provide up to 60 kW of power. Aerojet Rocketdyne is developing the 12 kW flight Hall thrusters to be used for transferring the PPE and the Habitat and Logistics Outpost (HALO) module to NRHO. Work is continuing on the development testing, and these results will be described in the paper. The project has also recently completed its critical design review and is transitioning to the fabrication of the three flight thrusters. The 12 kW Hall thrusters are being developed under the NASA Advanced Electric Propulsion System (AEPS) program. As part of the AEPS program, AR built two Engineering Test Unit (ETU) Hall thrusters based on the NASA HERMeS engine and conducted a series of tests to validate the design. One series of tests focused on environments and functional testing, while the other series was mainly focused on long duration test blocks. Results from these tests were used to compare with NASA data from the HERMeS thruster. The comparison of the test results showed no change to the critical performance and lifetime parameters, which enabled the next phase of the program to proceed. Currently testing is continuing on the Engineering Development Units (EDU) as part of the flight qualification activities. The successful completion of the CDR serves as the starting point for the flight thruster fabrication, which is now underway to support the launch of the Gateway modules in 2024. The development and qualification of the AEPS 12 kW Hall thrusters is proceeding well. As the program completes CDR and transitions into flight builds of the three 12 kW Hall thrusters that will be used to transfer the combined PPE and HALO stack to the NRHO, the results of the development testing are reviewed in this presentation, and a status of the program and future plans is provided. The launch of the two Gateway modules and the transfer of this large payload to cislunar orbit will mark a significant milestone in electric propulsion, as it will demonstrate the ability of SEP to transfer very large payloads over great distances. This establishes the precedent that could lead to cargo transfers from the Earth to the Moon or even to Mars using SEP.

Hall thrusters↗

FY 2021 Filter Test for TRU Waste Drum POC Proof-of-Concept Unit

Continuing last year’s (fiscal year 2020) work, a Proof-of-Concept (POC) instrument was developed to assess the functionality of filters on transuranic waste containers (commonly called 55 Gallon ring-top drums) without requiring removal of the drum lid. The purpose of this work is to determine the air flow and pressure characteristics associated with filter clogging, filter pressure drop, headspace volume, leakage around the lid seal and influence of the additional filter on a bag-out bag.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

FY2022 Filter Test for TRU Waste Drum Prototype Unit

Continuing last year’s (fiscal year 2021) work, a prototype instrument and an NPI-6 Integrated Work Document (IWD) were developed to assess the functionality of filters on transuranic waste containers (commonly called 55 Gallon ring-top drums) without requiring the removal of the drum lid. The purpose of this work is to determine the air flow and pressure characteristics associated with filter clogging, filter pressure drop at a fixed flow rate, and leakage around the lid seal. The FY22 objectives included: (A) Development of prototype device, (B) Drafting an IWD document, (C) Defining a filter clogging parameter, (D) Assessing filter damage due to over-pressure events, and (E) A path forward to obtain approval of the system safety filters in compliance with P101-16 Industrial Ventilation – non HVACR (LANL 2022).

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Space Suit Portable Life Support System (PLSS) 2.0 Pre-Installation Acceptance (PIA) Testing

Following successful completion of the space suit Portable Life Support System (PLSS) 1.0 development and testing in 2011, the second system-level prototype, PLSS 2.0, was developed in 2012 to continue the maturation of the advanced PLSS design. This advanced PLSS is intended to reduce consumables, improve reliability and robustness, and incorporate additional sensing and functional capabilities over the current Space Shuttle/International Space Station Extravehicular Mobility Unit (EMU) PLSS. PLSS 2.0 represents the first attempt at a packaged design comprising first generation or later component prototypes and medium fidelity interfaces within a flight-like representative volume. Pre-Installation Acceptance (PIA) is carryover terminology from the Space Shuttle Program referring to the series of test sequences used to verify functionality of the EMU PLSS prior to installation into the Space Shuttle airlock for launch. As applied to the PLSS 2.0 development and testing effort, PIA testing designated the series of 27 independent test sequences devised to verify component and subsystem functionality, perform in situ instrument calibrations, generate mapping data, define set-points, evaluate control algorithms, evaluate hardware performance against advanced PLSS design requirements, and provide quantitative and qualitative feedback on evolving design requirements and performance specifications. PLSS 2.0 PIA testing was carried out in 2013 and 2014 using a variety of test configurations to perform test sequences that ranged from stand-alone component testing to system-level testing, with evaluations becoming increasingly integrated as the test series progressed. Each of the 27 test sequences was vetted independently, with verification of basic functionality required before completion. Because PLSS 2.0 design requirements were evolving concurrently with PLSS 2.0 PIA testing, the requirements were used as guidelines to assess performance during the tests; after the completion of PIA testing, test data served to improve the fidelity and maturity of design requirements as well as plans for future advanced PLSS functional testing.

Anchondo, Ian↗

Rapid Biochemical Analysis on the International Space Station (ISS): Preparing for Human Exploration of the Moon and Mars

The Lab-on-a-Chip Application Development - Portable Test System, known as LOCAD-PTS, was launched to the International Space Station (ISS) aboard Space Shuttle Discovery (STS-116) on December 9th,2006. Since that time, it has remained onboard ISS and has been operated by the crew on 10 separate occasions LOCAD-PTS is a handheld device for rapid biochemical analysis; it consists of a spectrophotometer, a series of interchangeable cartridges, a pipette and several clean/sterilized swabbing kits to obtain samples from ISS surfaces. Sampling, quantitative analysis and data retrieval is performed onboard, therefore reducing the need to return samples to Earth. Less than 20 minutes are required from sampling to data, significantly faster than existing culture-based methods on ISS, which require 3-5 days. Different cartridges are available for the detection of different target molecules (simply by changing the formulation within each cartridge), thereby maximizing the benefit and applications addressed by a single instrument. Initial tests on ISS have focused on the detection of the bact.erial macromolecule endotoxin, a component of bacterial cell walls. LOCAD-PTS detects endotoxin with a cartridge that contains a formulation known as Limulus Amebocyte Lysate (LAL) assay. LAL is derived from blood of the horseshoe crab, Limulus polyphemus, and detects enodotoxin with an enzyme cascade that triggers generation Of a yellow colored dye, p-nitroanaline. The more p-nitroanaline product, the more endotoxin is in the original sample. To enable quantitative analysis, the absorbance of this color is measured by LOCAD-PTS through a 395 nm filter and compared with an internal calibration curve, to provide a reading on the LED display that ranges from 0.05 Endotoxin Units (EU)/ml to 5 EU/ml. Several surface sites were analyzed within ISS between March 2007 and February 2008, including multiple locations in the US Laboratory Destiny, Node 1 Unity, AMock, and Service Module Zvezda. The goals of this initial study were to i) test the cleanliness of reagents/supplies on orbit, ii) test the crew's ability to collect and process a sample in microgravity without contamination, iii) demonstrate nominal function of the LOCAD-PTS, and iv) provide a general survey of endotoxin within the ISS. The surface sites varied greatly in terms of their frequency-of-use and material texture/composition; from relatively smooth aluminum, to fabric, to the room temperature vulcanizing (RTV) rubber of a Extravehicular Mobility Unit (EMU) spacesuit. Results showed that: i) the swabbing kits and reagents remained clean on orbit, ii) the crew could collect and process a sample without contamination, and iii) the LOCAD-PTS functioned nominally in > 99% of the 55 tests completed. We will present detailed results of the survey of endotoxin on ISS surfaces. These results and technology are important in the near-term - by providing an extra tool in the toolbox for ISS microbial monitoring. They are also important in the longer term as valuable preparation for human exploration of the Moon and Mars. One of the proposed science goals for the human exploration of Mars will be to detect and characterize any indigenous biological molecules that may exist on the Martian surface. To achieve that goal, the crew must have the technology available onboard to differentiate indigenous biology from any terrestrial biological material brought to Mars by the spacecraft and crew (termed 'forward contamination'). The LAL assay is already one of the official methods used by NASA's planetary protection program to certify cleanliness of interplanetary robotic spacecraft prior to launch; and therefore endotoxin is a good marker of forward contamination (as well as other microbial molecules detectable with LOCAD-PTS e.g. box-1, 3-glucan and lipoteichoic acid). Furthermore, the distribution and abundance of these molecules on the ISS provides a good indicator of what to expect on the Crew Exploratioehicle Orion, the lunar lander Antares, and future crewed spacecraft destined for Mars. In addition, technology such as LOCAD-PTS has been proposed to help evaluate forward contamination during lunar surface operations by the crew, as preparation for the human exploration of Mars.

Maule, J.↗