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NASA NTRS1992

Electrical power integration for lunar operations

Electrical power for future lunar operations is expected to range from a few kilowatts for an early human outpost to many megawatts for industrial operations in the 21st century. All electrical power must be imported as chemical, solar, nuclear, or directed energy. The slow rotation of the Moon and consequent long lunar night impose severe mass penalties on solar systems needing night delivery from storage. The cost of power depends on the cost of the power systems the cost of its transportation to the Moon, operating cost, and, of course, the life of the power system. The economic feasibility of some proposed lunar ventures depends in part on the cost of power. This paper explores power integration issues, costs, and affordability in the context of the following representative lunar ventures: (1) early human outpost (10 kWe); (2) early permanent lunar base, including experimental ISMU activities (100 kWe); (3) lunar oxygen production serving an evolved lunar base (500 kWe); (4) lunar base production of specialized high-value products for use on Earth (5 kWe); and (5) lunar mining and production of helium-3 (500 kWe). The schema of the paper is to project likely costs of power alternatives (including integration factors) in these power ranges, to select the most economic, to determine power cost contribution to the product or activities, to estimate whether the power cost is economically acceptable, and, finally, to offer suggestions for reaching acceptability where cost problems exist.

Woodcock, Gordon↗

NASA NTRS2010

Autonomous System for Monitoring the Integrity of Composite Fan Housings

A low-cost and reliable system assesses the integrity of composite fan-containment structures. The system utilizes a network of miniature sensors integrated with the structure to scan the entire structural area for any impact events and resulting structural damage, and to monitor degradation due to usage. This system can be used to monitor all types of composite structures on aircraft and spacecraft, as well as automatically monitor in real time the location and extent of damage in the containment structures. This diagnostic information is passed to prognostic modeling that is being developed to utilize the information and provide input on the residual strength of the structure, and maintain a history of structural degradation during usage. The structural health-monitoring system would consist of three major components: (1) sensors and a sensor network, which is permanently bonded onto the structure being monitored; (2) integrated hardware; and (3) software to monitor in-situ the health condition of in-service structures.

Qing, Xinlin P.↗

NASA NTRS2005

Smart Sensors' Role in Integrated System Health Management

During the last decade, there has been a major effort in the aerospace industry to reduce the cost per pond of payload and become competitive in the international market. Competition from Europe, Japan, and China has reduced this cost to almost a third from 1990 to 2000. This cost has leveled in recent years to an average price of around $12,000/pound of payload. One of NASA's goals is to promote the development of technologies to reduce this cost by a factor of 10 or more Exploration of space, specially manned exploration missions, involves very complex launch and flight vehicles, associated ground support systems, and extensive human support during all phases of the mission. When considering the Space Shuttle Program, we can see that vehicle and ground support systems' processing, operation, and maintenance represent a large percentage of the program cost and time. Reducing operating, processing and maintenance costs will greatly reduce the cost of Exploration programs. The Integrated System Health Management (ISHM) concept is one of the technologies that will help reduce these operating, processing and maintenance costs. ISHM is an integrated health monitoring system applicable to both flight and ground systems. It automatically and autonomously acquires information from sensors and actuators and processes that information using the ISHM-embedded knowledge. As a result, it establishes the health of the system based on the acquired information and its prior knowledge. When this concept is fully implemented, ISHM systems shall be able to perform failure prediction and remediation before actual hard failures occurs, preventing its costly consequences. Data sources, sensors, and their associated data acquisition systems, constitute the foundation of the system. A smart sensing architecture is required to support the acquisition of reliable, high quality data, required by the ISHM. A thorough definition of the smart sensor architectures, their embedded diagnostic agents, and communication protocols need to be established and standardized to allow the embedding and exchange of health information among sensors and ISHM. This workshop is aimed to foster the exchange of ideas and lessons learned between government, industry and academia to aid in the establishment of ISHM (and smart sensors) standards and guidelines as well as to identify present technology gaps that will have to be overcome to successfully achieve this goal.

Perotti, Jose M.↗

NASA NTRS2005

CoMET: Cost and Mass Evaluation Tool for Spacecraft and Mission Design

New technology in space exploration is often developed without a complete knowledge of its impact. While the immediate benefits of a new technology are obvious, it is harder to understand its indirect consequences, which ripple through the entire system. COMET is a technology evaluation tool designed to illuminate how specific technology choices affect a mission at each system level. COMET uses simplified models for mass, power, and cost to analyze performance parameters of technologies of interest. The sensitivity analysis that CoMET provides shows whether developing a certain technology will greatly benefit the project or not. CoMET is an ongoing project approaching a web-based implementation phase. This year, development focused on the models for planetary daughter craft, such as atmospheric probes, blimps and balloons, and landers. These models are developed through research into historical data, well established rules of thumb, and engineering judgment of experts at JPL. The model is validated by corroboration with JpL advanced mission studies. Other enhancements to COMET include adding launch vehicle analysis and integrating an updated cost model. When completed, COMET will allow technological development to be focused on areas that will most drastically improve spacecraft performance.

Bieber, Ben S.↗

NASA NTRSDate not supplied

Lessons Learned in Space Life Support System Testing

The earlier problems can be found and corrected, the easier and cheaper it is to fix them. Doing less testing saves cost and time but doing too little testing increases the risk of operational failures causing large costs and delays. Integrated test is necessary to determine if the subsystems work together and the overall architecture performs as intended. This report reviews the testing lessons learned from the NASA Systems Engineering Handbook, a National Research Council report, and five reviews of International Space Station (ISS) lessons learned. The five reviews all mention two important points. First, that testing should be performed on the final integrated system, one as close as possible to the intended flight system. Second, “test as you fly,” while operating as planned in an environment as close as possible to the expected flight environment. Other lessons are the need for extensive preflight ground testing, the need to establish and defend an adequate budget, the problems using protoflight hardware on ISS, and the benefit of having ISS as a zero gravity test bed. The major ISS life support systems, carbon dioxide, water recycling, and oxygen recovery, were protoflight systems with little testing before launch to ISS. The failure rates these systems have been much greater than predicted and this has caused dissatisfaction with the protoflight approach. The more costly traditional approach is building qualification and test units in addition to flight units. The test units are used to test, analyze, and fix failure modes. Other work shows that there is an optimum cost-effective intuitive appeal of a human ecosystem in space.

Life support↗

NASA NTRSDate not supplied

Lessons Learned in Space Life Support System Testing

The earlier problems can be found and corrected, the easier and cheaper it is to fix them. Doing less testing saves cost and time but doing too little testing increases the risk of operational failures causing large costs and delays. Integrated test is necessary to determine if the subsystems work together and the overall architecture performs as intended. This report reviews the testing lessons learned from the NASA Systems Engineering Handbook, a National Research Council report, and five reviews of International Space Station (ISS) lessons learned. The five reviews all mention two important points. First, that testing should be performed on the final integrated system, one as close as possible to the intended flight system. Second, “test as you fly,” while operating as planned in an environment as close as possible to the expected flight environment. Other lessons are the need for extensive preflight ground testing, the need to establish and defend an adequate budget, the problems using protoflight hardware on ISS, and the benefit of having ISS as a zero gravity test bed. The major ISS life support systems, carbon dioxide removal, water recycling, and oxygen recovery, were protoflight systems with little testing before launch to ISS. The failure rates of these systems have been much greater than predicted and this has caused dissatisfaction with the protoflight approach. The more costly traditional approach builds qualification and test units in addition to flight units. The test units are used to find, analyze, and fix failure modes. Other work shows that there is an optimum cost-effective amount of testing when redundant systems must have a specified reliability and confidence.

Harry W. Jones↗

NASA NTRS1974

The Energy Systems Optimization Computer Program /ESOP/ developed for Modular Integrated Utility Systems /MIUS/ analysis

A significant energy and cost savings can be obtained by integrating various utility services (space heating and cooling, electrical power generation, solid waste disposal, potable water, and waste water treatment) into a single unit which provides buildings or groups of buildings with these services. This paper presents a description of a computer program, called the Energy Systems Optimization Program (ESOP). This program predicts the loads, energy requirements, equipment sizes, and life-cycle costs of alternative methods of meeting these utility requirements. The program has been used extensively for performing energy analyses of Modular Integrated Utility Systems (MIUS).

Ferden, S. L.↗

NASA NTRS1988

Developing integrated parametric planning models for budgeting and managing complex projects

The applicability of integrated parametric models for the budgeting and management of complex projects is investigated. Methods for building a very flexible, interactive prototype for a project planning system, and software resources available for this purpose, are discussed and evaluated. The prototype is required to be sensitive to changing objectives, changing target dates, changing costs relationships, and changing budget constraints. To achieve the integration of costs and project and task durations, parametric cost functions are defined by a process of trapezoidal segmentation, where the total cost for the project is the sum of the various project cost segments, and each project cost segment is the integral of a linearly segmented cost loading function over a specific interval. The cost can thus be expressed algebraically. The prototype was designed using Lotus-123 as the primary software tool. This prototype implements a methodology for interactive project scheduling that provides a model of a system that meets most of the goals for the first phase of the study and some of the goals for the second phase.

Etnyre, Vance A.↗

NASA NTRS1974

Orbital flux integrations: Parameter values for effective computer time reductions

To improve computer utilization and to reduce the cost of orbital flux integrations, the effects of integration parameters 'duration' (T) and 'stepsize' (delta t) on integration results were investigated. Over given ranges of T and delta t, and within specified acceptable accuracy restraints, optimal values of these parameters were established for circular subsynchronous trajectories, in terms of the variables altitude (H) and inclination (i). It is shown that (1) above a certain statistically important value, duration is independent of both h and i; (2) stepsize has a relative altitude dependence; and (3) stepsize is not a function of inclination. The substantial savings in computer time are discussed along with the possibility of greater savings by relaxing accuracy restrictions while not exceeding the minimum model-associated uncertainty factors of the environments.

Stassinopoulos, E. G.↗

NASA NTRS2002

Contactless conductivity detector for microchip capillary electrophoresis

A microfabricated electrophoresis chip with an integrated contactless conductivity detection system is described. The new contactless conductivity microchip detector is based on placing two planar sensing aluminum film electrodes on the outer side of a poly(methyl methacrylate) (PMMA) microchip (without contacting the solution) and measuring the impedance of the solution in the separation channel. The contactless route obviates problems (e.g., fouling, unwanted reactions) associated with the electrode-solution contact, offers isolation of the detection system from high separation fields, does not compromise the separation efficiency, and greatly simplifies the detector fabrication. Relevant experimental variables, such as the frequency and amplitude of the applied ac voltage or the separation voltage, were examined and optimized. The detector performance was illustrated by the separation of potassium, sodium, barium, and lithium cations and the chloride, sulfate, fluoride, acetate, and phosphate anions. The response was linear (over the 20 microM-7 mM range) and reproducible (RSD = 3.4-4.9%; n = 10), with detection limits of 2.8 and 6.4 microM (for potassium and chloride, respectively). The advantages associated with the contactless conductivity detection, along with the low cost of the integrated PMMA chip/detection system, should enhance the power and scope of microfluidic analytical devices.

NASA Center JPL↗

NASA NTRS1975

Development of a monolithic GaAs integrated optical transmitter

The paper discusses a program designed for the development of a GaAs IOC transmitter consisting of a monolithic surface laser whose output is coupled into patterned channel waveguides. Modulation and switching of the radiation occur in the waveguide circuit and are controlled separately. These structures are to be fabricated monolithically on a single semiconductor chip with each device amenable to integrated low-cost manufacture. The waveguide outputs of the IOC transmitter will be coupled to single mode optical fibers which form a transmission cable. The properties of the semiconductors (Ga,Al)As and (Ga,In)As permit performance of each of the basic functions included in the device considered. The concept of monolithic nondiscrete GaAs diode lasers is examined along with optical stripline channel waveguides and electro-optic channel waveguide modulators and switches.

Blum, F. A.↗

NASA NTRS1977

Preliminary Solar Sail Design and Fabrication Assessment: Spinning Sail Blade, Square Sail Sheet

Blade design aspects most affecting producibility and means of measurement and control of length, scallop, fullness and straightness requirements and tolerances were extensively considered. Alternate designs of the panel seams and edge reinforcing members are believed to offer advantages of seam integrity, producibility, reliability, cost and weight. Approaches to and requirements for highly specialized metalizing methods, processes and equipment were studied and identified. Alternate methods of sail blade fabrication and related special machinery, tooling, fixtures and trade offs were examined. A preferred and recommended approach is also described. Quality control plans, inspection procedures, flow charts and special test equipment associated with the preferred manufacturing method were analyzed and are discussed.

Daniels, J. B.↗

NASA NTRS1979

Design, processing and testing of LSI arrays, hybrid microelectronics task

Mathematical cost models previously developed for hybrid microelectronic subsystems were refined and expanded. Rework terms related to substrate fabrication, nonrecurring developmental and manufacturing operations, and prototype production are included. Sample computer programs were written to demonstrate hybrid microelectric applications of these cost models. Computer programs were generated to calculate and analyze values for the total microelectronics costs. Large scale integrated (LST) chips utilizing tape chip carrier technology were studied. The feasibility of interconnecting arrays of LSU chips utilizing tape chip carrier and semiautomatic wire bonding technology was demonstrated.

Himmel, R. P.↗

NASA NTRS1980

Mixed mode missions - Designing payloads to match flight opportunities

Shuttle missions have usually been viewed as being devoted to a single mission mode. But full utilization of the STS capabilities as a platform for space research dictates a flexible strategy toward payload integration and mission design. Simple interfaces, single disciplines, and large design and resource margins point the way toward larger payload integration and operation costs. Payloads for early missions (i.e., OSTA-1, OSS-1, and MEA) are used as illustrations to support this argument. The implications of this approach for future NASA plans as well as for new STS operational concepts are considered.

Noblitt, B. G.↗

NASA NTRS1981

Cost goals

Cost goal activities for the point focusing parabolic dish program are reported. Cost goals involve three tasks: (1) determination of the value of the dish systems to potential users; (2) the cost targets of the dish system are set out; (3) the value side and cost side are integrated to provide information concerning the potential size of the market for parabolic dishes. The latter two activities are emphasized.

Hoag, J.↗

NASA NTRS1981

Advanced composite aileron for L-1011 transport aircraft: Design and analysis

Detail design of the composite aileron has been completed. The aileron design is a multi-rib configuration with single piece upper and lower covers mechanically fastened to the substructure. Covers, front, spar and ribs are fabricated with graphite/epoxy tape or fabric composite material. The design has a weight savings of 23 percent compared to the aluminum aileron. The composite aileron has 50 percent fewer fasteners and parts than the metal aileron and is predicted to be cost competitive. Structural integrity of the composite aileron was verified by structural analysis and an extensive test program. Static, failsafe, and vibration analyses have been conducted on the composite aileron using finite element models and specialized computer programs for composite material laminates. The fundamental behavior of the composite materials used in the aileron was determined by coupon tests for a variety of environmental conditions. Critical details of the design were interrogated by static and fatigue tests on full-scale subcomponents and subassemblies of the aileron.

Griffin, C. F.↗

NASA NTRS1985

Glass/Epoxy Door Panel for Automobiles

Lightweight panel cost-effective. Integrally-molded intrusion strap key feature of composite outer door panel. Strap replaces bulky and heavy steel instrusion beam of conventional door. Standard steel inner panel used for demonstration purposes. Door redesigned to exploit advantages of composite outer panel thinner. Outer panel for automobilie door, made of glass/epoxy composite material, lighter than conventional steel door panel, meets same strength requirements, and less expensive.

Bauer, J. L. JR.↗

NASA NTRS1981

SPF/DB primary structure for supersonic aircraft (T-38 horizontal stabilizer)

The structural integrity and potential cost savings of superplastic forming/diffusion bonding (SPF/DB) titanium structure for future Supersonic Cruise Research (SCR) and military aircraft primary structure applications was demonstrated. Using the horizontal stabilizer of the T-38 aircraft as a baseline, the structure was redesigned to the existing criteria and loads, using SPF/DB titanium technology. The general concept of using a full-depth sandwich structure which is attached to a steel spindle, was retained. Trade studies demonstrated that the optimum design should employ double-truss, sinewave core in the deepest section of the surface, making a transition to single-truss core in the thinner areas at the leading and trailing edges and at the tip. At the extreme thin edges of the surface, the single-truss core was changed to dot core to provide for gas passages during the SPF/DB process. The selected SPF/DB horizontal stabilizer design consisted of a one-piece SPF/DB sinewave truss core panel, a trunnion fitting, and reinforcing straps. The fitting and the straps were mechanically fastened to the SPF/DB panel.

Delmundo, A. R.↗