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At least 181 records · Page 10

Development of Lead Free Energy Absorber for Space Shuttle Blast Container

The Space Shuttle vehicle (SSV) is connected to the mobile launch platform (MLP) by four aft skirt hold down studs on each solid rocket booster (SRB). Prior to lift-off, the frangible nuts inside the aft skirt blast containers (BC) are severed into two nut halves by two pyrotechnic booster cartridges. This action releases the SSV and allows the hold down studs to eject through the aft skirt bore and then down into the MLP. USBI has been tasked to upgrade the BC for two specific reasons; 1. to eliminate lead for environmental concerns, and 2. to reduce the chance of nut recontact with the holddown stud. Nut recontact with the stud has been identified as a likely contributor to stud hangups. This upgrade will replace the lead liner with an aluminum foam material. The aluminum foam used as a energy absorber is a proven design in many other aerospace/defense applications. Additional benefits of using the open cell, energy absorbent aluminum foam in place of the solid lead liner are: A. Lead handling/ exposure, and possible contamination, along with hazardous waste disposal will be eliminated; B. Approximately 200 lbs. weight savings will be contributed to each Space Shuttle flight by using aluminum foam over lead; C. The new aluminum liner is designed to catch all shrapnel from frangible nuts thus virtually eliminating chance of foreign object debris (FOD) exiting the HDP, and causing potential damage to the vehicle; D. Potential of using the lighter aluminum liner over lead, allows for easier assembly and disassembly of blast container elements, also allowing for improvements in safety, operator handling, and efficiency of operations. Six BC firing tests will be required to determine if the new liner material will perform in a way to decrease the chance of stud hangups and enhance the ability of the BC to retain blast debris. Testing will be performed at the Kennedy Space Center (KSC) facility known as the Launch Equipment Test Facility (LETF), and will simulate the SRB hold- down post, with actual BC hardware and pyrotechnics assembled, and then test fired. Initial testing was performed in 1997 using a frangible nut in a static drop test over lead and aluminum foam sheet materials. The aluminum foam showed a dramatic improvement of energy absorption over the lead liner material. Proof-of-Principle testing at the KSC-LETF commenced in May, 1998, and is expected to be completed by June, 1998.

Ingram, T.↗

X-38 Bolt Retractor Subsystem Separation Demonstration

The Flight Robotics Laboratory FRL successfully demonstrated the X-38 bolt retractor subsystem (BRS). The BRS design was proven safe by testing in the Pyrotechnic Shock Facility (PSI) before being demonstrated in the FRL. This Technical Memorandum describes the BRS, FRL, PSF, and interface hardware. Bolt retraction time, spacecraft simulator acceleration, and a force analysis are also presented. The purpose of the demonstration was to show the FRL capability for spacecraft separation testing using pyrotechnics. Although a formal test was not performed due to schedule and budget constraints, the data will show that the BRS is a successful design concept and the FRL is suitable for future separation tests.

Rugless, Fedoria↗

Design and Demonstration of Bolt Retractor Separation System for X-38 Deorbit Propulsion Stage

A separation system was designed for the X-38 experimental crew return vehicle program to allow the Deorbit Propulsion Stage (DPS) to separate from the X-38 lifting body during reentry operations. The configuration chosen was a spring-loaded plunger, known as the Bolt Retractor Subsystem (BRS), that retracts each of the six DPS-to-lifting body attachment bolts across the interface plane after being triggered by a separation nut mechanism. The system was designed to function on the ground in an atmospheric environment as well as in space. The BRS provides the same functionality as that of a completely pyrotechnic shear separation system that would normally be considered ideal for this application, but at a much lower cost. This system also could potentially be applied to future space station crew return vehicles. The design goal of 40 ms retraction time was successfully met in a series of demonstrations performed at the NASA Marshall Space Flight Center s Pyrotechnic Shock Facility (PSF) and Flight Robotics Laboratory (FRL). It must be emphasized that a full-scale test series was not performed on the BRS due to program schedule and cost constraints.

Ahmed, Raf↗

Pyroshock Environments Characterized for Spacecraft Missions

Pyrotechnic shock, or pyroshock, is the transient response of a structure to loading induced by the ignition of pyrotechnic (explosive or propellant activated) devices. These devices are typically used to separate structural systems (e.g., separate a spacecraft from a launch vehicle) and deploy appendages (e.g., solar panels). Pyroshocks are characterized by high peak acceleration, high-frequency content, and short duration. Because of their high acceleration and high-frequency, pyroshocks can cause spaceflight hardware to fail. Verifying by test that spaceflight hardware can withstand the anticipated shock environment is considered essential to mission success. The Earth Observing System (EOS) AM-1 spacecraft for NASA's Mission to Planet Earth is scheduled to be launched on an Atlas IIAS vehicle in 1999, and the NASA Lewis Research Center is the launch vehicle integrator for this NASA Goddard Space Flight Center spacecraft. The EOS spacecraft was subjected to numerous ground shock tests to verify that its scientific instruments and avionics components will withstand the shock-induced vibration produced when the spacecraft separates from the launch vehicle. Shock test data from these tests represent the third largest available pyroshock database in the United States. Future spacecraft missions will directly benefit from the knowledge gained from these tests. The payload separation system used for EOS is a new system that operates by firing six separation nuts. This system was tested to verify its functional operation and to characterize the resulting shock levels. The launch vehicle contractor (Lockheed Martin Astronautics) and spacecraft contractor (Lockheed Martin Missiles & Space) completed 16 separation test firings. This resulted in an unusually large amount of pyroshock data. Typically, only one or two pyroshock test firings are performed for a spacecraft mission. Because of the size of this separation system shock database, engineers were able to perform unique statistical analyses to characterize the distribution of the test data. For example, it was proven that the shock data follow a lognormal distribution, a concept often assumed but rarely proven. The test-to-test repeatability of the shock source level was analyzed, and the effects of various test configurations and separation nut production lots were examined and quantified. Engineers investigated the change in shock level as the shock traveled from the spacecraft separation interface to the avionics components of the upper stage and analyzed the effects of the structural fidelity (simulator versus real) of the components and their weight on vibrational response. In addition, the shock attenuation with distance and across joints was quantified and compared with concepts originally generated in 1970, and the effects of separation nut preload and firing sequences effects were examined. Because of this EOS shock testing and the analyses performed at NASA Lewis, a significant amount of new information on pyroshock and its characteristics is now available to the aerospace industry. We hope that this information will help future spacecraft test planners to perform better and cheaper spacecraft separation shock tests and to better understand their test data.

Hughes, William O.↗

NASA Space Mechanisms Handbook and Reference Guide Expanded Into CD-ROM Set

Several NASA missions suffered failures and anomalies due to problems in applying space mechanisms technology to specific projects. Research shows that engineers often lack either adequate knowledge of mechanism design or sufficient understanding of how mechanisms affect sensitive systems. The Space Mechanisms Project conducted a Lessons Learned study and published a Space Mechanisms Handbook to help space industry engineers avoid recurring design, qualification, and application problems. The Space Mechanisms Handbook written at the NASA Glenn Research Center details the state-of-the-art in space mechanisms design as of 1998. NASA's objective in developing this Space Mechanisms Handbook was to provide readily accessible information on such areas as space mechanisms design, mechanical component availability and use, testing and qualification of mechanical systems, and a listing of worldwide space mechanisms experts and testing facilities in the United States. This handbook has been expanded into a two-volume CD-ROM set in an Adobe Acrobat format. In addition to the handbook, the CD's include (1) the two volume Space Mechanisms Lessons Learned Study, (2) proceedings from all the NASA hosted Aerospace Mechanisms Symposia held through the year 2000, (3) the Space Materials Handbook, (4) the Lubrication Handbook for the Space Industry, (5) the Structural & Mechanical Systems Long-Life Assurance Design Guidelines, (6) the Space Environments and Effects Source-Book, (7) the Spacecraft Deployable Appendages manual, (8) the Fastener Design Manual, (9) A Manual for Pyrotechnic Design, Development and Qualification, (10) the Report on Alternative Devices to Pyrotechnics on Spacecraft, and (11) Gearing (a manual). In addition, numerous other papers on tribology and lubrication are included.This technical summary of the project provides information on how to obtain the handbook and related information.

Fusaro, Robert L.↗

A Method for Determining Autoignition Temperatures Resulting from Varying Rapid Rise Rates

Pyrotechnic and explosive devices are widely used in the aerospace industry to provide reliable, lightweight initiation components in ignition systems, cartridge actuated devices, escape and ejection systems, and many other applications. There are two major mechanisms for initiation of the pyrotechnic powders: heat and shock. Of powders initiated by heat, we have little information on the temperature required for ignition in the normal functioning time (milliseconds) of the device. The known autoignition temperatures obtained from standard tests provide data from days down to minutes with temperatures increasing as heating time decreases. In order to better understand this relationship, and to make computer models, improved data are needed.

Hagopian, Michael↗

New Generation Power System for Space Applications

The Deep Space Avionics (DSA) Project is developing a new generation of power system building blocks. Using application specific integrated circuits (ASICs) and power switching modules a scalable power system can be constructed for use on multiple deep space missions including future missions to Mars, comets, Jupiter and its moons. The key developments of the DSA power system effort are five power ASICs and a mod ule for power switching. These components enable a modular and scalab le design approach, which can result in a wide variety of power syste m architectures to meet diverse mission requirements and environments . Each component is radiation hardened to one megarad) total dose. The power switching module can be used for power distribution to regular spacecraft loads, to propulsion valves and actuation of pyrotechnic devices. The number of switching elements per load, pyrotechnic firin gs and valve drivers can be scaled depending on mission needs. Teleme try data is available from the switch module via an I2C data bus. The DSA power system components enable power management and distribution for a variety of power buses and power system architectures employing different types of energy storage and power sources. This paper will describe each power ASIC#s key performance characteristics as well a s recent prototype test results. The power switching module test results will be discussed and will demonstrate its versatility as a multip urpose switch. Finally, the combination of these components will illu strate some of the possible power system architectures achievable fro m small single string systems to large fully redundant systems.

power switching↗

Toggle release

A pyrotechnic actuated structural release device 10 which is mechanically two fault tolerant for release. The device 10 comprises a fastener plate 11 and fastener body 12, each attachable to a different one of a pair of structures to be joined. The fastener plate 11 and body 12 are fastenable by a toggle 13 supported at one end on the fastener plate and mounted for universal pivotal movement thereon. At its other end which is received in a central opening in the fastener body 12 and adapted for limited pivotal movement therein the toggle 13 is restrained by three retractable latching pins 61 symmetrically disposed in equiangular spacing about the axis of the toggle 13 and positionable in latching engagement with an end fitting on the toggle. Each pin 61 is individually retractable by combustion of a pyrotechnic charge 77, the expanding gases of which are applied to a pressure receiving face 67 on the latch pin 61 to effect its retraction from the toggle. While retraction of all three pins 62 releases the toggle, the fastener is mechanically two fault tolerant since the failure of any single one or pair of the latch pins to retract results in an asymmetrical loading on the toggle and its pivotal movement to effect a release. An annular bolt 18 is mounted on the fastener plate 11 as a support for the socket mounting 30, 37 of the toggle whereby its selective axial movement provides a means for preloading the toggle.

Graves, Thomas J.↗

Apollo Spacecraft and Saturn V Launch Vehicle Pyrotechnics/Explosive Devices

The Apollo Mission employs more than 210 pyrotechnic devices per mission.These devices are either automatic of commanded from the Apollo spacecraft systems. All devices require high reliability and safety and most are classified as either crew safety critical or mission critical. Pyrotechnic devices have a wide variety of applications including: launch escape tower separation, separation rocket ignition, parachute deployment and release and electrical circuit opening and closing. This viewgraph presentation identifies critical performance, design requirements and safety measures used to ensure quality, reliability and performance of Apollo pyrotechnic/explosive devices. The major components and functions of a typical Apollo pyrotechnic/explosive device are listed and described (initiators, cartridge assemblies, detonators, core charges). The presentation also identifies the major locations and uses for the devices on: the Command and Service Module, Lunar Module and all stages of the launch vehicle.

Interbartolo, Michael↗

Estimating Shock Spectra: Extensions beyond GEVS

Shock response spectra (SRS) are the standard description of some vibration environments on spacecraft for equipment qualification. For shock events produced by pyrotechnic devices, SRS can have significant frequency content as high as 10 kHz. It is difficult to construct and analyze finite element models that can resolve dynamic behavior at such high frequencies. GEVS provides simple, empirically based methods for approximating the SRS for a wide variety of shock events. It begins with a base SRS according to the type of pyrotechnic device, and then provides attenuation relations to adjust this SRS according to distance from the shock source, the type of structural frame and the properties of any structural joints between the source and equipment. In our paper we extend GEVS to include more detailed information about the spacecraft structure. To retain the general framework of GEVS, we begin with a base SRS and adjust this SRS using attenuation relations. We use modal and traveling wave concepts to derive the attenuation relations for simple canonical structures. Then we show how these concepts can be used to analyze more complex structures using finite element mode shapes to explicitly calculate the attenuation factors. Since the low- to mid-frequency finite element modal information is extrapolated to obtain the low- to high-frequency attenuation relations, the resulting attenuated SRS is formulated as an upper bound rather than as mean predicted values. We illustrate the extended GEVS approach by analyzing the impact response of composite tubes and the shock response of the STEREO spacecraft.

Igusa, Takeru↗

Liquid Oxygen/Liquid Methane Test Results of the RS-18 Lunar Ascent Engine at Simulated Altitude Conditions at NASA White Sands Test Facility

Tests were conducted with the RS-18 rocket engine using liquid oxygen (LO2) and liquid methane (LCH4) propellants under simulated altitude conditions at NASA Johnson Space Center White Sands Test Facility (WSTF). This project is part of NASA's Propulsion and Cryogenics Advanced Development (PCAD) project. "Green" propellants, such as LO2/LCH4, offer savings in both performance and safety over equivalently sized hypergolic propulsion systems in spacecraft applications such as ascent engines or service module engines. Altitude simulation was achieved using the WSTF Large Altitude Simulation System, which provided altitude conditions equivalent up to ~122,000 ft (~37 km). For specific impulse calculations, engine thrust and propellant mass flow rates were measured. LO2 flow ranged from 5.9 - 9.5 lbm/sec (2.7 - 4.3 kg/sec), and LCH4 flow varied from 3.0 - 4.4 lbm/sec (1.4 - 2.0 kg/sec) during the RS-18 hot-fire test series. Propellant flow rate was measured using a coriolis mass-flow meter and compared with a serial turbine-style flow meter. Results showed a significant performance measurement difference during ignition startup due to two-phase flow effects. Subsequent cold-flow testing demonstrated that the propellant manifolds must be adequately flushed in order for the coriolis flow meters to give accurate data. The coriolis flow meters were later shown to provide accurate steady-state data, but the turbine flow meter data should be used in transient phases of operation. Thrust was measured using three load cells in parallel, which also provides the capability to calculate thrust vector alignment. Ignition was demonstrated using a gaseous oxygen/methane spark torch igniter. Test objectives for the RS-18 project are 1) conduct a shakedown of the test stand for LO2/methane lunar ascent engines, 2) obtain vacuum ignition data for the torch and pyrotechnic igniters, and 3) obtain nozzle kinetics data to anchor two-dimensional kinetics codes. All of these objectives were met with the RS-18 data and additional testing data from subsequent LO2/methane test programs in 2009 which included the first simulated-altitude pyrotechnic ignition demonstration of LO2/methane.

Melcher, John C., IV↗

Sea-Level Flight Demonstration and Altitude Characterization of a LO2/LCH4 Based Accent Propulsion Lander

A 1,500 lbf thrust-class liquid oxygen (LO2)/Liquid Methane (LCH4) rocket engine was developed and tested at both sea-level and simulated altitude conditions. The engine was fabricated by Armadillo Aerospace (AA) in collaboration with NASA Johnson Space Center. Sea level testing was conducted at Armadillo Aerospace facilities at Caddo Mills, TX. Sea-level tests were conducted using both a static horizontal test bed and a vertical take-off and landing (VTOL) test bed capable of lift-off and hover-flight in low atmosphere conditions. The vertical test bed configuration is capable of throttling the engine valves to enable liftoff and hover-flight. Simulated altitude vacuum testing was conducted at NASA Johnson Space Center White Sands Test Facility (WSTF), which is capable of providing altitude simulation greater than 120,000 ft equivalent. The engine tests demonstrated ignition using two different methods, a gas-torch and a pyrotechnic igniter. Both gas torch and pyrotechnic ignition were demonstrated at both sea-level and vacuum conditions. The rocket engine was designed to be configured with three different nozzle configurations, including a dual-bell nozzle geometry. Dual-bell nozzle tests were conducted at WSTF and engine performance data was achieved at both ambient pressure and simulated altitude conditions. Dual-bell nozzle performance data was achieved over a range of altitude conditions from 90,000 ft to 50,000 ft altitude. Thrust and propellant mass flow rates were measured in the tests for specific impulse (Isp) and C* calculations.

Collins, Jacob↗

Simulator for Testing Spacecraft Separation Devices

A report describes the main features of a system for testing pyrotechnic and mechanical devices used to separate spacecraft and modules of spacecraft during flight. The system includes a spacecraft simulator [also denoted a large mobility base (LMB)] equipped with air thrusters, sensors, and data-acquisition equipment. The spacecraft simulator floats on air bearings over an epoxy-covered concrete floor. This free-flotation arrangement enables simulation of motion in outer space in three degrees of freedom: translation along two orthogonal horizontal axes and rotation about a vertical axis. The system also includes a static stand. In one application, the system was used to test a bolt-retraction system (BRS) intended for separation of the lifting-body and deorbit-propulsion stages of the X- 38 spacecraft. The LMB was connected via the BRS to the static stand, then pyrotechnic devices that actuate the BRS were fired. The separation distance and acceleration were measured. The report cites a document, not yet published at the time of reporting the information for this article, that is said to present additional detailed information.

Johnston, Nick↗

Swell Sleeves for Testing Explosive Devices

A method of testing explosive and pyrotechnic devices involves exploding the devices inside swell sleeves. Swell sleeves have been used previously for measuring forces. In the present method, they are used to obtain quantitative indications of the energy released in explosions of the devices under test. A swell sleeve is basically a thick-walled, hollow metal cylinder threaded at one end to accept a threaded surface on a device to be tested (see Figure 1). Once the device has been tightly threaded in place in the swell sleeve, the device-and-swell-sleeve assembly is placed in a test fixture, then the device is detonated. After the explosion, the assembly is removed from the test fixture and placed in a coordinate-measuring machine for measurement of the diameter of the swell sleeve as a function of axial position. For each axial position, the original diameter of the sleeve is subtracted from the diameter of the sleeve as swollen by the explosion to obtain the diametral swelling as a function of axial position (see Figure 2). The amount of swelling is taken as a measure of the energy released in the explosion. The amount of swelling can be compared to a standard amount of swelling to determine whether the pyrotechnic device functioned as specified.

Hinkel, Todd J.↗

Command Interface ASIC - Analog Interface ASIC Chip Set

A command interface application-specific integrated circuit (ASIC) and an analog interface ASIC have been developed as a chip set for remote actuation and monitoring of a collection of switches, which can be used to control generic loads, pyrotechnic devices, and valves in a high-radiation environment. The command interface ASIC (CIA) can be used alone or in combination with the analog interface ASIC (AIA). Designed primarily for incorporation into spacecraft control systems, they are also suitable for use in high-radiation terrestrial environments (e.g., in nuclear power plants and facilities that process radioactive materials). The primary role of the CIA within a spacecraft or other power system is to provide a reconfigurable means of regulating the power bus, actuating all valves, firing all pyrotechnic devices, and controlling the switching of power to all switchable loads. The CIA is a mixed-signal (analog and digital) ASIC that includes an embedded microcontroller with supporting fault-tolerant switch control and monitoring circuitry that is capable of connecting to a redundant set of interintegrated circuit (I(sup 2)C) buses. Commands and telemetry requests are communicated to the CIA. Adherence to the I(sup 2)C bus standard helps to reduce development costs by facilitating the use of previously developed, commercially available components. The AIA is a mixed-signal ASIC that includes the analog circuitry needed to connect the CIA to a custom higher powered version of the I(sup 2)C bus. The higher-powered version is designed to enable operation with bus cables longer than those contemplated in the I(sup 2)C standard. If there are multiple higher-power I(sup 2)C-like buses, then there must an AIA between the CIA and each such bus. The AIA includes two identical interface blocks: one for the side-A I(sup 2)C clock and data buses and the other for the side B buses. All the AIAs on each side are powered from a common power converter module (PCM). Sides A and B of the I(sup 2)C buses are electrically isolated from each other (see figure). They are also isolated from the CIA by use of transformer coupling of signals between the AIA blocks and the CIA.

Ruiz, Baldes↗

Solid Rocket Booster (SRB) - Evolution and Lessons Learned During the Shuttle Program

The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Obsolescence issues occasionally required component recertification. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. Assembly and integration of the booster subsystems was a unique process and acceptance testing of reused hardware components was required for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.

Kanner, Howard S.↗

Solid Rocket Booster (SRB) Flight System Integration at Its Best

The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads, environments and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. However, the in-flight data and postflight assessment process revealed the hardware was affected much more strongly than originally anticipated. Assembly and integration of the booster subsystems required acceptance testing of reused hardware components for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges and technical issues, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.

Wood, T. David↗