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NASA NTRS1975

Seminar on Understanding Digital Control and Analysis in Vibration Test Systems, part 2

A number of techniques for dealing with important technical aspects of the random vibration control problem are described. These include the generation of pseudo-random and true random noise, the control spectrum estimation problem, the accuracy/speed tradeoff, and control correction strategies. System hardware, the operator-system interface, safety features, and operational capabilities of sophisticated digital random vibration control systems are also discussed.

Source record↗

NASA NTRS2011

Dynamic Loads Generation for Multi-Point Vibration Excitation Problems

A random-force method has been developed to predict dynamic loads produced by rocket-engine random vibrations for new rocket-engine designs. The method develops random forces at multiple excitation points based on random vibration environments scaled from accelerometer data obtained during hot-fire tests of existing rocket engines. This random-force method applies random forces to the model and creates expected dynamic response in a manner that simulates the way the operating engine applies self-generated random vibration forces (random pressure acting on an area) with the resulting responses that we measure with accelerometers. This innovation includes the methodology (implementation sequence), the computer code, two methods to generate the random-force vibration spectra, and two methods to reduce some of the inherent conservatism in the dynamic loads. This methodology would be implemented to generate the random-force spectra at excitation nodes without requiring the use of artificial boundary conditions in a finite element model. More accurate random dynamic loads than those predicted by current industry methods can then be generated using the random force spectra. The scaling method used to develop the initial power spectral density (PSD) environments for deriving the random forces for the rocket engine case is based on the Barrett Criteria developed at Marshall Space Flight Center in 1963. This invention approach can be applied in the aerospace, automotive, and other industries to obtain reliable dynamic loads and responses from a finite element model for any structure subject to multipoint random vibration excitations.

Shen, Lawrence↗

NASA NTRS1992

The design concept of the 6-degree-of-freedom hydraulic shaker at ESTEC

The European Space Agency (ESA) has decided to extend its test facilities at the European Space and Technology Center (ESTEC) at Noordwijk, The Netherlands, by implementing a 6-degree-of-freedom hydraulic shaker. This shaker will permit vibration testing of large payloads in the frequency range from 0.1 Hz to 100 Hz. Conventional single axis sine and random vibration modes can be applied without the need for a configuration change of the test set-up for vertical and lateral excitations. Transients occurring during launch and/or landing of space vehicles can be accurately simulated in 6-degrees-of-freedom. The performance requirements of the shaker are outlined and the results of the various trade-offs, which are investigated during the initial phase of the design and engineering program are provided. Finally, the resulting baseline concept and the anticipated implementation plan of the new test facility are presented.

Brinkman, P. W.↗

NASA NTRS1974

A Statistical Approach to Establishing Subsystem Environmental Test Specifications

Results are presented of a research task to evaluate structural responses at various subsystem mounting locations during spacecraft level test exposures to the environments of mechanical shock, acoustic noise, and random vibration. This statistical evaluation is presented in the form of recommended subsystem test specifications for these three environments as normalized to a reference set of spacecraft test levels and are thus suitable for extrapolation to a set of different spacecraft test levels. The recommendations are dependent upon a subsystem's mounting location in a spacecraft, and information is presented on how to determine this mounting zone for a given subsystem.

Keegan, W. B.↗

NASA NTRS2005

Integrated Structural Analysis and Test Program

An integrated structural-analysis and structure-testing computer program is being developed in order to: Automate repetitive processes in testing and analysis; Accelerate pre-test analysis; Accelerate reporting of tests; Facilitate planning of tests; Improve execution of tests; Create a vibration, acoustics, and shock test database; and Integrate analysis and test data. The software package includes modules pertaining to sinusoidal and random vibration, shock and time replication, acoustics, base-driven modal survey, and mass properties and static/dynamic balance. The program is commanded by use of ActiveX controls. There is minimal need to generate command lines. Analysis or test files are selected by opening a Windows Explorer display. After selecting the desired input file, the program goes to a so-called analysis data process or test data process, depending on the type of input data. The status of the process is given by a Windows status bar, and when processing is complete, the data are reported in graphical, tubular, and matrix form.

Kaufman, Daniel↗

NASA NTRS1996

Force limited vibration testing of Cassini spacecraft cosmic dust analyser

The testing of the cosmic dust analyzer for the Cassini mission using the force limited method in order to avoid overtesting and to verify the ability of the specimen design to withstand the loads during launch and cruise, is reported on. In order to implement the method, force gages, fixtures and a test controller are required and the test specimen is subjected to sine vibration, random vibration and half sine shock. The practical aspects of the use of the force limited method are described. Due to the high loads and the weak design of the structural element, a notching method is used which provides the possibility of limiting the excitation to flight expected levels.

Jahn, Heiko↗

NASA NTRS2014

Evaluation of Polymer Hermetically Sealed Tantalum Capacitors

Polymer cathode tantalum capacitors have lower ESR (equivalent series resistance) compared to other types of tantalum capacitors and for this reason have gained popularity in the electronics design community. Their use allows improved performance of power supply systems along with substantial reduction of size and weight of the components used. However, these parts have poor thermal stability and can degrade in humid environments. Polymer hermetically sealed (PHS) capacitors avoid problems related to environmental degradation of molded case parts and can potentially replace current wet and solid hermetically sealed capacitors. In this work, PHS capacitors manufactured per DLA LAM DWG#13030 are evaluated for space applications. Several lots of capacitors manufactured over period from 2010 to 2014 were tested for the consistency of performance, electrical and thermal characteristics, highly accelerated life testing, and robustness under reverse bias and random vibration conditions. Special attention was given to analysis of leakage currents and the effect of long-term high temperature storage on capacitors in as is condition and after hermeticity loss. The results show that PHS capacitors might be especially effective for low-temperature applications or for system requiring a cold start-up. Additional screening and qualification testing have been recommended to assure the necessary quality of capacitors for space projects.

ferrite beads↗

NASA NTRS1994

Experimental analysis of thread movement in bolted connections due to vibrations

The objective of this study was to identify the main design parameters contributing to loosening of bolts due to vibration and to identify their relative importance and degree of contribution to bolt loosening. Vibration testing was conducted on a shaketable with a controlled-random input in the dynamic testing laboratory of the Structural Test Division of MSFC. Test specimens which contained one test bolt were vibrated for a fixed amount of time and percentage of pre-load loss was measured. Each specimen tested implemented some combination of eleven design parameters as dictated by the design of experiment methodology employed. The eleven design parameters were: bolt size (diameter), lubrication on bolt, hole tolerance, initial pre-load, nut locking device, grip length, thread pitch, lubrication between mating materials, class of fit, joint configuration and mass of configuration. These parameters were chosen for this experiment because they are believed to be the design parameters having the greatest impact on bolt loosening. Two values of each design parameter were used and each combination of parameters tested was subjected to two different directions of vibration and two different g-levels of vibration. One replication was made for each test to gain some indication of experimental error and repeatability and to give some degree of statistical credibility to the data, resulting in a total of 96 tests being performed. The results of the investigation indicated that nut locking devices, joint configuration, fastener size, and mass of configuration were significant in bolt loosening due to vibration. The results of this test can be utilized to further research the complex problem of bolt loosening due to vibration.

Ramey, G. ED↗

NASA NTRS1995

Experimental analysis of thread movement in bolted connections due to vibrations

This is the final report of research project NAS8-39131 #33 sponsored by NASA's George C. Marshall Space Flight Center (MSFC) and carried out by the Civil Engineering Department of Auburn University (Auburn, Alabama) and personnel of MSFC. The objective of this study was to identify the main design parameters contributing to the loosening of bolts due to vibration and to identify their relative importance and degree of contribution to bolt loosening. Vibration testing was conducted on a shaketable with a controlled-random input in the dynamic testing laboratory of the Structural Test Division of MSFC. Test specimens which contained one test bolt were vibrated for a fixed amount of time and a percentage of pre-load loss was measured. Each specimen tested implemented some combination of eleven design parameters as dictated by the design of experiment methodology employed. The eleven design parameters were: bolt size (diameter), lubrication on bolt, hole tolerance, initial pre-load, nut locking device, grip length, thread pitch, lubrication between mating materials, class of fit, joint configuration, and mass of configuration. These parameters were chosen for this experiment because they are believed to be the design parameters having the greatest impact on bolt loosening. Two values of each design parameter were used and each combination of parameters tested was subjected to two different directions of vibration and two different g-levels of vibration. One replication was made for each test to gain some indication of experimental error and repeatability and to give some degree of statistical credibility to the data, resulting in a total of 96 tests being performed. The results of the investigation indicated that nut locking devices, joint configuration, fastener size, and mass of configuration were significant in bolt loosening due to vibration. The results of this test can be utilized to further research the complex problem of bolt loosening due to vibration.

Ramsey, G. ED↗

NASA NTRS2001

Vibration Test Demonstrated Dynamic Capability of an Operating Stirling Convertor

The NASA Glenn Research Center and the U.S. Department of Energy are currently developing a high-efficiency, long-life, free piston Stirling convertor for use as an advanced spacecraft power system for future NASA missions. As part of this development, a Stirling Technology Demonstrator Converter (TDC), developed by Stirling Technology Company for the Department of Energy, was vibration tested at Glenn's Structural Dynamics Laboratory in November and December 1999. This testing demonstrated that the Stirling TDC is able to withstand the harsh random vibration (20 to 2000 Hz) seen during a typical spacecraft launch and to survive with no structural damage or functional power performance degradation, thereby enabling its use in future spacecraft power systems. Glenn and Stirling personnel conducted tests on a single 55 We TDC. The purpose was to characterize the TDC's structural response to vibration and to determine if the TDC could survive the vibration criteria established by the Jet Propulsion Laboratory for launch environments. The TDC was operated at full-stroke and full power conditions during the vibration testing.

Hughes, William O.↗

NASA NTRS2001

CM-2 Environmental / Modal Testing of Spacehab Racks

Combined environmental/modal vibration testing has been implemented at the NASA Glenn Research Center's Structural Dynamics Laboratory. The benefits of combined vibration testing are that it facilitates test article modal characterization and vibration qualification testing. The Combustion Module-2 (CM-2) is a space experiment that launches on Shuttle mission STS 107 in the SPACEHAB Research Double Module. The CM-2 flight hardware is integrated into a SPACEHAB single and double rack. CM-2 rack level combined vibration testing was recently completed on a shaker table to characterize the structure's modal response and verify the random vibration response. Control accelerometers and limit force gauges, located between the fixture and rack interface, were used to verify the input excitation. Results of the testing were used to verify the loads and environments for flight on the Shuttle.

McNelis, Mark E.↗

NASA NTRS2001

CM-2 Environmental/Modal Testing of SPACEHAB Racks

Combined environmental/modal vibration testing has been implemented at the NASA Glenn Research Center's Structural Dynamics Laboratory. The benefits of combined vibration testing are that it facilitates test article modal characterization and vibration qualification testing. The Combustion Module-2 (CM-2) is a space experiment that will launch on shuttle mission STS-107 in the SPACEHAB Research Double Module. The CM-2 flight hardware is integrated into a SPACEHAB single and double rack. CM-2 rack-level combined vibration testing was recently completed on a shaker table to characterize the structure's modal response and verify the random vibration response. Control accelerometers and limit force gauges, located between the fixture and rack interface, were used to verify the input excitation. Results of the testing were used to verify the loads and environments for flight on the shuttles.

McNelis, Mark E.↗

NASA NTRS1972

Effect of vertical active vibration isolation on tracking performance and on ride qualities

An investigation to determine the effect on pilot performance and comfort of an active vibration isolation system for a commercial transport pilot seat is reported. The test setup consisted of: a hydraulic shaker which produced random vertical vibration inputs; the active vibration isolation system; the pilot seat; the pilot control wheel and column; the side-arm controller; and a two-axis compensatory tracking task. The effects of various degrees of pilot isolation on short-term (two-minute) tracking performance and comfort were determined.

Dimasi, F. P.↗

NASA NTRS2018

Testing and Maturing a Mass Translating Mechanism for a Deep Space CubeSat

Near Earth Asteroid (NEA) Scout is a deep space satellite set to launch aboard NASA’s Exploration Mission 1. The spacecraft fits within a CubeSat standard 6U (about 300 x 200 x 100 mm) and is designed to travel 1 AU over a 2.5 year mission to observe NEA VG 1991. The spacecraft will use an 86 square meter solar sail to maneuver from lunar orbit to the NEA. One of the critical mechanisms aboard NEA Scout, the Active Mass Translator (AMT), has gone through rigorous design and test cycles since its conception in July of 2015. The AMT is a two-axis translation table required to balance the spacecraft’s center of mass (CM) and solar sail center of pressure (CP) while also trimming disturbance torque created by off-nominal sail conditions. The AMT has very limited mass and volume requirements, but is still required to deliver a large translation range—about 160 x 68 mm—at sub mm accuracy and precision. The system must accommodate and protect a shielded wire harness and coax cables during translation. Lastly, the system has been constrained to operate in complete exposure to space with limited power and data budgets for mechanical and thermal needs. The NEA Scout team has developed and carried out a rigorous test suite for the prototype and engineering development unit (EDU). These tests uncovered numerous design failures and led to many failure investigations and iteration cycles. This paper will site each discovery and discuss at length the most surprising and difficult failures to date as the NEA Scout AMT moved through functional, random vibration, thermal vacuum, harnessing, and design life verification testing. A paper was previously presented at the 43rd Aerospace Mechanisms Symposia entitled, “Development of a High Performance, Low Profile Translation Table with Wire Feedthrough for a Deep Space CubeSat”. This paper will make note of specific lessons learned from the test activities: testing ideologies for high-risk missions, thermal mitigation design for small mechanisms, non-flight qualified stepper motor accommodation, harnessing volume allocation/design, and ground testing of mechanisms developed for zero-g environments.

Few, Alex↗

NASA NTRS2007

Implementation of Leak Test Methods for the International Space Station (ISS) Elements, Systems and Components

The International Space Station (ISS has Qualification and Acceptance Environmental Test Requirements document, SSP 41172 that includes many environmental tests such as Thermal vacuum & Cycling, Depress/Repress, Sinusoidal, Random, and Acoustic Vibration, Pyro Shock, Acceleration, Humidity, Pressure, Electromatic Interference (EMI)/Electromagnetic Compatibility (EMCO), etc. This document also includes (13) leak test methods for Pressure Integrity Verification of the ISS Elements, Systems, and Components. These leak test methods are well known, however, the test procedure for specific leak test method shall be written and implemented paying attention to the important procedural steps/details that, if omitted or deviated, could impact the quality of the final product and affect the crew safety. Such procedural steps/details for different methods include, but not limited to: - Sequence of testing, f or example, pressurization and submersion steps for Method I (Immersion); - Stabilization of the mass spectrometer leak detector outputs fo r Method II (vacuum Chamber or Bell jar); - Proper data processing an d taking a conservative approach while making predictions for on-orbit leakage rate for Method III(Pressure Change); - Proper Calibration o f the mass spectrometer leak detector for all the tracer gas (mostly Helium) Methods such as Method V (Detector Probe), Method VI (Hood), Method VII (Tracer Probe), Method VIII(Accumulation); - Usage of visibl ility aides for Method I (Immersion), Method IV (Chemical Indicator), Method XII (Foam/Liquid Application), and Method XIII (Hydrostatic/Visual Inspection); While some methods could be used for the total leaka ge (either internal-to-external or external-to-internal) rate requirement verification (Vacuum Chamber, Pressure Decay, Hood, Accumulation), other methods shall be used only as a pass/fail test for individual joints (e.g., welds, fittings, and plugs) or for troubleshooting purposes (Chemical Indicator, Detector Probe, Tracer Probe, Local Vacuum Chamber, Foam/Liquid Application, and Hydrostatic/Visual Inspection). Any isolation of SSP 41172 requirements have led to either retesting of hardware or accepting a risk associated with the potential system or component pressure integrity problem during flight.

Underwood, Steve↗

NASA NTRS1975

Flight Flutter Testing of the P6M

On the P6M the shake behavior, i.e., the response to random excitation at subcritical speeds of lowly damped airplane modes, is as important as the actual flutter speed. The approach is to first study the problem by means of analyses and wind-tunnel tests. These predictions are compared with flight test data obtained by spectral analysis of tape recordings of the airplane vibration responses to random aerodynamic turbulence. A similar spectrum analysis approach was used in high speed wind-tunnel tests. A resonance excitation technique was developed for low speed wind-tunnel testing, and well defined V-g curves were obtained. The effect of various parameters on both shake and flutter of T-tails with and without dihedral were studied. Preliminary flight tests yielded good correlation; they also yielded interesting information concerning a low frequency transonic snaking mode, and excitation by shed vortices.

Kachadourian, G.↗

NASA NTRS1972

Slush hydrogen liquid level system

A discrete capacitance liquid level system developed is specifically for slush hydrogen, but applicable to LOX, LN2, LH2, and RP1 without modification is described. The signal processing portion of the system is compatible with conventional liquid level sensors. Compatibility with slush hydrogen was achieved by designing the sensor with adequate spacing, while retaining the electrical characteristics of conventional sensors. Tests indicate excellent stability of the system over a temperature range of -20 C to 70 C for the circuit and to cryogenic temperatures of the sensor. The sensor was tested up to 40 g's rms random vibration with no damage to the sensor. Operation with 305 m of cable between the sensor and signal processor was demonstrated. It is concluded that this design is more than adequate for most flight and ground applications.

Hamlet, J. F.↗

NASA NTRS1992

Environmental qualification testing of payload G-534, the Pool Boiling Experiment

Payload G-534, the prototype Pool Boiling Experiment (PBE), is scheduled to fly on the STS-47 mission in September 1992. This paper describes the purpose of the experiment and the environmental qualification testing program that was used to prove the integrity of the hardware. Component and box level vibration and thermal cycling tests were performed to give an early level of confidence in the hardware designs. At the system level, vibration, thermal extreme soaks, and thermal vacuum cycling tests were performed to qualify the complete design for the expected shuttle environment. The system level vibration testing included three axis sine sweeps and random inputs. The system level hot and cold soak tests demonstrated the hardware's capability to operate over a wide range of temperatures and gave wider latitude in determining which shuttle thermal attitudes were compatible with the experiment. The system level thermal vacuum cycling tests demonstrated the hardware's capability to operate in a convection free environment. A unique environmental chamber was designed and fabricated by the PBE team and allowed most of the environmental testing to be performed within the hardware build laboratory. The completion of the test program gave the project team high confidence in the hardware's ability to function as designed during flight.

Sexton, J. Andrew↗