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A demonstration of an intelligent control system for a reusable rocket engine

An Intelligent Control System for reusable rocket engines is under development at NASA Lewis Research Center. The primary objective is to extend the useful life of a reusable rocket propulsion system while minimizing between flight maintenance and maximizing engine life and performance through improved control and monitoring algorithms and additional sensing and actuation. This paper describes current progress towards proof-of-concept of an Intelligent Control System for the Space Shuttle Main Engine. A subset of identifiable and accommodatable engine failure modes is selected for preliminary demonstration. Failure models are developed retaining only first order effects and included in a simplified nonlinear simulation of the rocket engine for analysis under closed loop control. The engine level coordinator acts as an interface between the diagnostic and control systems, and translates thrust and mixture ratio commands dictated by mission requirements, and engine status (health) into engine operational strategies carried out by a multivariable control. Control reconfiguration achieves fault tolerance if the nominal (healthy engine) control cannot. Each of the aforementioned functionalities is discussed in the context of an example to illustrate the operation of the system in the context of a representative failure. A graphical user interface allows the researcher to monitor the Intelligent Control System and engine performance under various failure modes selected for demonstration.

Musgrave, Jeffrey L.↗

Time maintenance system for the BMDO MSX spacecraft

The Johns Hopkins University Applied Physics Laboratory (APL) is responsible for designing and implementing a clock maintenance system for the Ballistic Missile Defense Organizations (BMDO) Midcourse Space Experiment (MSX) spacecraft. The MSX spacecraft has an on-board clock that will be used to control execution of time-dependent commands and to time tag all science and housekeeping data received from the spacecraft. MSX mission objectives have dictated that this spacecraft time, UTC(MSX), maintain a required accuracy with respect to UTC(USNO) of +/- 10 ms with a +/- 1 ms desired accuracy. APL's atomic time standards and the downlinked spacecraft time were used to develop a time maintenance system that will estimate the current MSX clock time offset during an APL pass and make estimates of the clock's drift and aging using the offset estimates from many passes. Using this information, the clock's accuracy will be maintained by uplinking periodic clock correction commands. The resulting time maintenance system is a combination of offset measurement, command/telemetry, and mission planning hardware and computing assets. All assets provide necessary inputs for deciding when corrections to the MSX spacecraft clock must be made to maintain its required accuracy without inhibiting other mission objectives. The MSX time maintenance system is described as a whole and the clock offset measurement subsystem, a unique combination of precision time maintenance and measurement hardware controlled by a Macintosh computer, is detailed. Simulations show that the system estimates the MSX clock offset to less than+/- 33 microseconds.

Hermes, Martin J.↗

Command Preprocessor for Radiotelescopes and Microwave Antennas

The LQG controllers, designed for the NASA Deep Space Network antennas have small tracking errors and are resistant to wind disturbances. However, during antenna slewing, they induce limit cycling caused by the violation of the antenna rate and acceleration limits. This problem can be avoided by introduction of a command that does not exceed the limits. The command preprocessor presented in this paper generates a command that is equal to the original command if the latter does not exceed the limits, and varies with the maximal (or minimal) allowable rate and acceleration if the limits are met or exceeded. It is comparatively simple since it requires only knowledge of the command at the current and the previous time instants, while other known preprocessors require knowledge of the terminal state and the acquisition time. Thus, the presented preprocessor is more suitable for implementation. In this article analysis of the preprocessor is presented. Also the performances of the preprocessor itself, and of the antenna with the preprocessor is illustrated with typical antenna commands.

Gawronski, Wodek↗

Low-Power Operation and Plasma Characterization of a Qualification Model SPT-140 Hall Thruster for NASA Science Missions

Hall thruster systems based on commercial product lines can potentially lead to lower cost electric propulsion (EP) systems for deep space science missions. A 4.5-kW SPT-140 Hall thruster presently under qualification testing by SSL leverages the substantial heritage of the SPT-100 being flown on Russian and US commercial satellites. The Jet Propulsion Laboratory is exploring the use of commercial EP systems, including the SPT-140, for deep space science missions, and initiated a program to evaluate the SPT-140 in the areas of low power operation and thruster operating life. A qualification model SPT-140 designated QM002 was evaluated for operation and plasma properties along channel centerline, from 4.5 kW to 0.8 kW. Additional testing was performed on a development model SPT-140 designated DM4 to evaluate operation with a Moog proportional flow control valve (PFCV). The PFCV was commanded by an SSL engineering model PPU-140 Power Processing Unit (PPU). Performance measurements on QM002 at 0.8 kW discharge power were 50 mN of thrust at a total specific impulse of 1250 s, a total thruster efficiency of 0.38, and discharge current oscillations of under 3% of the mean current. Steady-state operation at 0.8 kW was demonstrated during a 27 h firing. The SPT-140 DM4 was operated in closed-loop control of the discharge current with the PFCV and PPU over discharge power levels of 0.8-4.5 kW. QM002 and DM4 test data indicate that the SPT-140 design is a viable candidate for NASA missions requiring power throttling down to low thruster input power.

Garner, Charles E.↗

The Mariner Venus Mercury flight data subsystem.

The flight data subsystem (FDS) discussed handles both the engineering and scientific measurements performed on the MVM'73. It formats the data into serial data streams, and sends it to the modulation/demodulation subsystem for transmission to earth or to the data storage subsystem for storage on a digital tape recorder. The FDS is controlled by serial digital words, called coded commands, received from the central computer sequencer of from the ground via the modulation/demodulation subsystem. The eight major blocks of the FDS are: power converter, timing and control, engineering data, memory, memory input/output and control, nonimaging data, imaging data, and data output. The FDS incorporates some 4000 components, weighs 17 kg, and uses 35 W of power. General data on the mission and spacecraft are given.

Whitehead, P. B.↗

Closed-loop autonomous docking system

An autonomous docking system is provided which produces commands for the steering and propulsion system of a chase vehicle used in the docking of that chase vehicle with a target vehicle. The docking system comprises a passive optical target affixed to the target vehicle and comprising three reflective areas including a central area mounted on a short post, and tracking sensor and process controller apparatus carried by the chase vehicle. The latter apparatus comprises a laser diode array for illuminating the target so as to cause light to be reflected from the reflective areas of the target; a sensor for detecting the light reflected from the target and for producing an electrical output signal in accordance with an image of the reflected light; a signal processor for processing the electrical output signal in accordance with an image of the reflected light; a signal processor for processing the electrical output signal and for producing, based thereon, output signals relating to the relative range, roll, pitch, yaw, azimuth, and elevation of the chase and target vehicles; and a docking process controller, responsive to the output signals produced by the signal processor, for producing command signals for controlling the steering and propulsion system of the chase vehicle.

Dabney, Richard W.↗

Experimental investigation of an accelerometer controlled automatic braking system

An investigation was made to determine the feasibility of an automatic braking system for arresting the motion of an airplane by sensing and controlling braked wheel decelerations. The system was tested on a rotating drum dynamometer by using an automotive tire, wheel, and disk-brake assembly under conditions which included two tire loadings, wet and dry surfaces, and a range of ground speeds up to 70 knots. The controlling parameters were the rates at which brake pressure was applied and released and the Command Deceleration Level which governed the wheel deceleration by controlling the brake operation. Limited tests were also made with the automatic braking system installed on a ground vehicle in an effort to provide a more realistic proof of its feasibility. The results of this investigation indicate that a braking system which utilizes wheel decelerations as the control variable to restrict tire slip is feasible and capable of adapting to rapidly changing surface conditions.

Dreher, R. C.↗

Computer-aided design of flight control systems

A computer program is presented for facilitating the development and assessment of flight control systems, and application to a control design is discussed. The program is a computer-aided control-system design program based on direct digital synthesis of a proportional-integral-filter controller with scheduled linear-quadratic-Gaussian gains and command generator tracking of pilot inputs. The FlightCAD system concentrates on aircraft dynamics, flight-control systems, stability and performance, and has practical engineering applications.

Stengel, Robert F.↗

Control Design Strategies to Enhance Long-Term Aircraft Structural Integrity

Over the operational lifetime of both military and civil aircraft, structural components are exposed to hundreds of thousands of low-stress repetitive load cycles and less frequent but higher-stress transient loads originating from maneuvering flight and atmospheric gusts. Micro-material imperfections in the structure, such as cracks and debonded laminates, expand and grow in this environment, reducing the structural integrity and shortening the life of the airframe. Extreme costs associated with refurbishment of critical load-bearing structural components in a large fleet, or altogether reinventoring the fleet with newer models, indicate alternative solutions for life extension of the airframe structure are highly desirable. Increased levels of operational safety and reliability are also important factors influencing the desirability of such solutions. One area having significant potential for impacting crack growth/fatigue damage reduction and structural life extension is flight control. To modify the airframe response dynamics arising from command inputs and gust disturbances, feedback loops are routinely applied to vehicles. A dexterous flight control system architecture senses key vehicle motions and generates critical forces/moments at multiple points distributed throughout the airframe to elicit the desired motion characteristics. In principle, these same control loops can be utilized to influence the level of exposure to harmful loads during flight on structural components. Project objectives are to investigate and/or assess the leverage control has on reducing fatigue damage and enhancing long-term structural integrity, without degrading attitude control and trajectory guidance performance levels. In particular, efforts have focused on the effects inner loop control parameters and architectures have on fatigue damage rate. To complete this research, an actively controlled flexible aircraft model and a new state space modeling procedure for crack growth have been utilized. Analysis of the analytical state space model for crack growth revealed the critical mathematical factors, and hence the physical mechanism they represent, that influenced high rates of airframe crack growth. The crack model was then exercised with simple load inputs to uncover and expose key crack growth behavior. To characterize crack growth behavior, both "short-term" laboratory specimen test type inputs and "long-term" operational flight type inputs were considered. Harmonic loading with a single overload revealed typical exponential crack growth behavior until the overload application, after which time the crack growth was retarded for a period of time depending on the overload strength. An optimum overload strength was identified which leads to maximum retardation of crack growth. Harmonic loading with a repeated overload of varying strength and frequency again revealed an optimum overload trait for maximizing growth retardation. The optimum overload strength ratio lies near the range of 2 to 3 with dependency on frequency. Experimental data was found to correlate well with the analytical predictions.

Newman, Brett A.↗

An overview of the pointing control system for NASA's Space Infra-red Telescope Facility (SIRTF)

This paper discusses the pointing control system for NASA's Space Infra-Red Telescope Facility (SIRTF). After an introduction to the SIRTF mission and telescope, an overview is given of the pointing control hardware, pointing control architecture, pointing requirements and capability, attitude constraints and commanding, attitude observers and required calibrations.

pointing control attitude estimation calibration↗

Wireless power charging using point of load controlled high frequency power converters

An apparatus for wirelessly charging a battery of an electric vehicle is provided with a point of load control. The apparatus includes a base unit for generating a direct current (DC) voltage. The base unit is regulated by a power level controller. One or more point of load converters can be connected to the base unit by a conductor, with each point of load converter comprising a control signal generator that transmits a signal to the power level controller. The output power level of the DC voltage provided by the base unit is controlled by power level controller such that the power level is sufficient to power all active load converters when commanded to do so by any of the active controllers, without generating excessive power that may be otherwise wasted.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Optimal Propellant Maneuver Flight Demonstrations on ISS

In this paper, first ever flight demonstrations of Optimal Propellant Maneuver (OPM), a method of propulsive rotational state transition for spacecraft controlled using thrusters, is presented for the International Space Station (ISS). On August 1, 2012, two ISS reorientations of about 180deg each were performed using OPMs. These maneuvers were in preparation for the same-day launch and rendezvous of a Progress vehicle, also a first for ISS visiting vehicles. The first maneuver used 9.7 kg of propellant, whereas the second used 10.2 kg. Identical maneuvers performed without using OPMs would have used approximately 151.1kg and 150.9kg respectively. The OPM method is to use a pre-planned attitude command trajectory to accomplish a rotational state transition. The trajectory is designed to take advantage of the complete nonlinear system dynamics. The trajectory choice directly influences the cost of the maneuver, in this case, propellant. For example, while an eigenaxis maneuver is kinematically the shortest path between two orientations, following that path requires overcoming the nonlinear system dynamics, thereby increasing the cost of the maneuver. The eigenaxis path is used for ISS maneuvers using thrusters. By considering a longer angular path, the path dependence of the system dynamics can be exploited to reduce the cost. The benefits of OPM for the ISS include not only reduced lifetime propellant use, but also reduced loads, erosion, and contamination from thrusters due to fewer firings. Another advantage of the OPM is that it does not require ISS flight software modifications since it is a set of commands tailored to the specific attitude control architecture. The OPM takes advantage of the existing ISS control system architecture for propulsive rotation called USTO control mode1. USTO was originally developed to provide ISS Orbiter stack attitude control capability for a contingency tile-repair scenario, where the Orbiter is maneuvered using its robotic manipulator relative to the ISS. Since 2005 USTO has been used for nominal ISS operations.

Bhatt, Sagar↗

Linear Actuator Has Long Stroke and High Resolution

The term precision linear actuator, direct drive ( PLADD ) refers to a robust linear actuator designed to be capable of repeatedly performing, over a lifetime of the order of 5 to 10 years, positioning maneuvers that include, variously, submicron increments or slews of the order of a centimeter. The PLADD is capable of both long stroke (120 mm) and high resolution (repeatable increments of 20 nm). Unlike precise linear actuators of prior design, the PLADD contains no gears, levers, or hydraulic converters. The PLADD, now at the prototype stage of development, is intended for original use as a coarse-positioning actuator in a spaceborne interferometer. The PLADD could also be adapted to terrestrial applications in which there are requirements for long stroke and high resolution: potential applications include medical imaging and fabrication of semiconductor devices. The PLADD (see figure) includes a commercially available ball-screw actuator driven directly by a commercially available three-phase brushless DC motor. The ball-screw actuator comprises a spring-preloaded ball nut on a ball screw that is restrained against rotation as described below. The motor is coupled directly (that is, without an intervening gear train) to a drive link that, in turn, is coupled to the ball nut. By eliminating the gear train, the direct-drive design eliminates the complexity, backlash, and potential for misalignment associated with a gear train. To prevent inadvertent movement, there is a brake that includes flexured levers compressed against the drive link by preload springs. This is a power-off brake: There are also piezoelectric stacks that can be activated to oppose the springs and push the levers away from the drive link. Hence, power must be applied to the piezoelectric stacks to release the drive link from braking. To help ensure long operational life, all of the mechanical drive components are immersed in an oil bath within hermetically sealed bellows. The outer end of the bellows holds the outer end of the ball screw, thereby preventing rotation of the ball screw. Positioning is controlled by an electronic control system that includes digital and analog subsystems that interact with the motor and brake and with two sensor/encoder units: a Hall-effect-sensor rotation encoder and a linear glass-scale encoder. This system implements a proportional + integral + derivative control algorithm that results in variation of voltage commands to each of the three pairs of windings of the brushless DC motor. In one of two alternative control modes, the voltages are applied to the windings in a trapezoidal commutation scheme on the basis of timing signals obtained from the Hall-effect sensors; this scheme yields relatively coarse positioning - 24 steps per motor revolution. The second control mode involves a sinusoidal commutation scheme in which the output of the linear glass-scale encoder is transposed to rotational increments to yield much finer position feedback - more than 400,000 steps per revolution.

Cook, Brant T.↗

Derivation of Equations of Motion and Model-based Control for 3D Rigid Body Approximation of LUVOIR

The Large UV/Optical/IR Surveyor (LUVOIR) is a conceptual space observatory under development by NASA Goddard Space Flight Center for the Astronomy and Astrophysics Decadal Survey. As with similar space telescopes, e.g., James Webb, this spacecraft will have ultra-stringent pointing stability requirements, i.e., on the order of miliarcseconds. Thus, the design of the LUVOIR attitude control system (ACS) may benefit from a model-based approach. In this document, we present an approximate model of the LUVOIR composed of two 3D rigid bodies connected by a 1-DOF rotary joint. From this model, we derive the nonlinear equations of motion, following the approach of Eric T. Stoneking [1], and linearize them about an arbitrary reference orientation. Using the subsequent state space representation, it is straightforward to compute a set of control gains (e.g., via the ”lqr” or ”place” commands in MATLAB). We conclude this memo with a comparison of our LQR approach with the existing PID slew controller designed by a former NASA intern.

William Bentz↗

Orion Entry Flight Control Stability and Performance

The Orion Spacecraft will be required to perform entry and landing functions for both Low Earth Orbit (LEO) and Lunar return missions, utilizing only the Command Module (CM) with its unique systems and GN&C design. This paper presents the current CM Flight Control System (FCS) design to support entry and landing, with a focus on analyses that have supported its development to date. The CM FCS will have to provide for spacecraft stability and control while following guidance or manual commands during exo-atmospheric flight, after Service Module separation, translational powered flight required of the CM, atmospheric flight supporting both direct entry and skip trajectories down to drogue chute deploy, and during roll attitude reorientation just prior to touchdown. Various studies and analyses have been performed or are on-going supporting an overall FCS design with reasonably sized Reaction Control System (RCS) jets, that minimizes fuel usage, that provides appropriate command following but with reasonable stability and control margin. Results from these efforts to date are included, with particular attention on design issues that have emerged, such as the struggle to accommodate sub-sonic pitch and yaw control without using excessively large jets that could have a detrimental impact on vehicle weight. Apollo, with a similar shape, struggled with this issue as well. Outstanding CM FCS related design and analysis issues, planned for future effort, are also briefly be discussed.

Strahan, Alan L.↗

Flux-Feedback Magnetic-Suspension Actuator

Flux-feedback magnetic-suspension actuator provides magnetic suspension and control forces having linear transfer characteristics between force command and force output over large range of gaps. Hall-effect devices used as sensors for electronic feedback circuit controlling currents flowing in electromagnetic windings to maintain flux linking suspended element at substantially constant value independent of changes in length of gap. Technique provides effective method for maintenance of constant flux density in gap and simpler than previous methods. Applications include magnetic actuators for control of shapes and figures of antennas and of precise segmented reflectors, magnetic suspensions in devices for storage of angular momentum and/or kinetic energy, and systems for control, pointing, and isolation of instruments.

Groom, Nelson J.↗

Design and Development of a 200-kW Turbo-Electric Distributed Propulsion Testbed

The National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (AFRC) (Edwards, California) is developing a Hybrid-Electric Integrated Systems Testbed (HEIST) Testbed as part of the HEIST Project, to study power management and transition complexities, modular architectures, and flight control laws for turbo-electric distributed propulsion technologies using representative hardware and piloted simulations. Capabilities are being developed to assess the flight readiness of hybrid electric and distributed electric vehicle architectures. Additionally, NASA will leverage experience gained and assets developed from HEIST to assist in flight-test proposal development, flight-test vehicle design, and evaluation of hybrid electric and distributed electric concept vehicles for flight safety. The HEIST test equipment will include three trailers supporting a distributed electric propulsion wing, a battery system and turbogenerator, dynamometers, and supporting power and communication infrastructure, all connected to the AFRC Core simulation. Plans call for 18 high performance electric motors that will be powered by batteries and the turbogenerator, and commanded by a piloted simulation. Flight control algorithms will be developed on the turbo-electric distributed propulsion system.

distributed↗

Flight evaluation of advanced controls and displays for transition and landing on the NASA V/STOL systems research aircraft

Flight experiments were conducted on Ames Research Center's V/STOL Systems Research Aircraft (VSRA) to assess the influence of advanced control modes and head-up displays (HUD's) on flying qualities for precision approach and landing operations. Evaluations were made for decelerating approaches to hover followed by a vertical landing and for slow landings for four control/display mode combinations: the basic YAV-8B stability augmentation system; attitude command for pitch, roll, and yaw; flightpath/acceleration command with translational rate command in the hover; and height-rate damping with translational-rate command. Head-up displays used in conjunction with these control modes provided flightpath tracking/pursuit guidance and deceleration commands for the decelerating approach and a mixed horizontal and vertical presentation for precision hover and landing. Flying qualities were established and control usage and bandwidth were documented for candidate control modes and displays for the approach and vertical landing. Minimally satisfactory bandwidths were determined for the translational-rate command system. Test pilot and engineer teams from the Naval Air Warfare Center, the Boeing Military Airplane Group, Lockheed Martin, McDonnell Douglas Aerospace, Northrop Grumman, Rolls-Royce, and the British Defense Research Agency participated in the program along with NASA research pilots from the Ames and Lewis Research Centers. The results, in conjunction with related ground-based simulation data, indicate that the flightpath/longitudinal acceleration command response type in conjunction with pursuit tracking and deceleration guidance on the HUD would be essential for operation to instrument minimums significantly lower than the minimums for the AV-8B. It would also be a superior mode for performing slow landings where precise control to an austere landing area such as a narrow road is demanded. The translational-rate command system would reduce pilot workload for demanding vertical landing tasks aboard ship and in confined land-based sites.

Franklin, James A.↗

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