Results for “Lessons learned” — Page 12

NASA NTRS2012

Human Systems Integration in Practice: Constellation Lessons Learned

NASA's Constellation program provided a unique testbed for Human Systems Integration (HSI) as a fundamental element of the Systems Engineering process. Constellation was the first major program to have HSI mandated by NASA's Human Rating document. Proper HSI is critical to the success of any project that relies on humans to function as operators, maintainers, or controllers of a system. HSI improves mission, system and human performance, significantly reduces lifecycle costs, lowers risk and minimizes re-design. Successful HSI begins with sufficient project schedule dedicated to the generation of human systems requirements, but is by no means solely a requirements management process. A top-down systems engineering process that recognizes throughout the organization, human factors as a technical discipline equal to traditional engineering disciplines with authority for the overall system. This partners with a bottoms-up mechanism for human-centered design and technical issue resolution. The Constellation Human Systems Integration Group (HSIG) was a part of the Systems Engineering and Integration (SE&I) organization within the program office, and existed alongside similar groups such as Flight Performance, Environments & Constraints, and Integrated Loads, Structures and Mechanisms. While the HSIG successfully managed, via influence leadership, a down-and-in Community of Practice to facilitate technical integration and issue resolution, it lacked parallel top-down authority to drive integrated design. This presentation will discuss how HSI was applied to Constellation, the lessons learned and best practices it revealed, and recommendations to future NASA program and project managers. This presentation will discuss how Human Systems Integration (HSI) was applied to NASA's Constellation program, the lessons learned and best practices it revealed, and recommendations to future NASA program and project managers on how to accomplish this critical function.

Zumbado, Jennifer Rochlis↗

NASA NTRSDate not supplied

Having a Come-Apart: Lessons Learned from Additively Manufactured Hardware Failures

NASA has been engaged with additively manufactured (AM) process and component development since the 2000’s. AM offers various technical advantages, such as enhanced hardware design complexity, part consolidation, and processing of novel alloys in addition to programmatic advantages for reduction in processing time and cost. The focus of much of the AM development at NASA has been to mature the various processes, characterize material properties, develop standards, produce demonstrator parts, and integrate AM hardware in liquid rocket engines. These aspects have been demonstrated through process and design iterations using a methodical characterization, test-fail-fix cycles, as well as application and dissemination of lessons learned. In addition to these fundamental demonstrations of the AM process and hardware development, alloys that provide performance advantages in the high temperature and high-pressure environments have been matured for use in rocket engines. These environments are challenging for any alloy and any design, and the AM process is required to fully meet the intended design requirements. The importance of proper AM process was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality resulted from an AM process issue. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. In part, such concerns motivate the AM certification approach that NASA has recently adopted in NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems”. This presentation provides an overview of the previously mentioned failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. The objective of this presentation is to provide awareness to the community working critical and non-critical AM components and the lessons learned on proper implementation of AM.

Additive Manufacturing↗

NASA NTRS2011

NASA Ares I Launch Vehicle Roll and Reaction Control Systems Lessons Learned

On April 15, 2010 President Barak Obama made the official announcement that the Constellation Program, which included the Ares I launch vehicle, would be canceled. NASA s Ares I launch vehicle was being designed to launch the Orion Crew Exploration Vehicle, returning humans to the moon, Mars, and beyond. It consisted of a First Stage (FS) five segment solid rocket booster and a liquid J-2X Upper Stage (US) engine. Roll control for the FS was planned to be handled by a dedicated Roll Control System (RoCS), located on the connecting interstage. Induced yaw or pitch moments experienced during FS ascent would have been handled by vectoring of the booster nozzle. After FS booster separation, the US Reaction Control System (ReCS) would have provided the US Element with three degrees of freedom control as needed. The lessons learned documented in this paper will be focused on the technical designs and producibility of both systems along with the partnership between NASA and Boeing, who was on contract to build the Ares I US Element, which included the FS RoCS and US ReCS. In regards to partnership, focus will be placed on integration along with technical work accomplished by Boeing with special emphasis on each task order. In summary, this paper attempts to capture key lessons learned that should be helpful in the development of future launch vehicle RCS designs.

Butt, Adam↗

NASA NTRS2010

Lessons Learned from the Kepler Mission and Space Telescope Management

This paper presents lessons learned over the course of several space telescope mission and instrument developments spanning two decades. These projects involved astronomical telescopes developed by the National Aeronautics and Space Administration (NASA) and were designed to further our understanding of the Universe. It is hoped that the lessons drawn from these experiences may be of use to future mission developers.

GALEX↗

DOE OSTI2021

Lessons Learned From the Prototypes of the MQXFA Low-Beta Quadrupoles for HL-LHC and Status of Production in the US

With the successful test of the first two pre-series magnets the US HL-LHC Accelerator Upgrade Project has started production of the MQXFA magnets to be used in Q1/Q3 inner triplet elements of the HL-LHC. This good start comes after the test of two prototypes with limited performance, and it demonstrates the importance of learning from past issues. Therefore, in this paper we want to share the most important lessons learned so far, focusing on those which may be more interesting for similar projects. Additionally, we will present the status of MQXFA fabrication in the US.

43 PARTICLE ACCELERATORS↗

NASA NTRS2014

Lessons Learned in the First Year Operating Software Defined Radios in Space

Operating three unique software defined radios (SDRs) in a space environment aboard the Space Communications and Navigation (SCaN) Testbed for over one year has provided an opportunity to gather knowledge useful for future missions considering using software defined radios. This paper provides recommendations for the development and use of SDRs, and it considers the details of each SDRs approach to software upgrades and operation. After one year, the SCaN Testbed SDRs have operated for over 1000 hours. During this time, the waveforms launched with the SDR were tested on-orbit to assure that they operated in space at the same performance level as on the ground prior to launch to obtain an initial on-orbit performance baseline. A new waveform for each SDR has been developed, implemented, uploaded to the flight system, and tested in the flight environment. Recommendations for SDR-based missions have been gathered from early development through operations. These recommendations will aid future missions to reduce the cost, schedule, and risk of operating SDRs in a space environment. This paper considers the lessons learned as they apply to SDR pre-launch checkout, purchasing space-rated hardware, flexibility in command and telemetry methods, on-orbit diagnostics, use of engineering models to aid future development, and third-party software. Each SDR implements the SCaN Testbed flight computer command and telemetry interface uniquely, allowing comparisons to be drawn. The paper discusses the lessons learned from these three unique implementations, with suggestions on the preferred approach. Also, results are presented showing that it is important to have full system performance knowledge prior to launch to establish better performance baselines in space, requiring additional test applications to be developed pre-launch. Finally, the paper presents the issues encountered with the operation and implementation of new waveforms on each SDR and proposes recommendations to avoid these issues.

radio equipment↗

NASA NTRS2015

Design Evolution of the Wide Field Infrared Survey Telescope using Astrophysics Focused Telescope Assets (WFIRST-AFTA) and Lessons Learned

The design of the Wide Field Infrared Survey Telescope using Astrophysics Focused Telescope Assets (WFIRST-AFTA) continues to evolve as each design cycle is analyzed. In 2012, two Hubble sized (2.4 m diameter) telescopes were donated to NASA from elsewhere in the Federal Government. NASA began investigating potential uses for these telescopes and identified WFIRST as a mission to benefit from these assets. With an updated, deeper, and sharper field of view than previous design iterations with a smaller telescope, the optical designs of the WFIRST instruments were updated and the mechanical and thermal designs evolved around the new optical layout. Beginning with Design Cycle 3, significant analysis efforts yielded a design and model that could be evaluated for Structural-Thermal-Optical-Performance (STOP) purposes for the Wide Field Imager (WFI) and provided the basis for evaluating the high level observatory requirements. Development of the Cycle 3 thermal model provided some valuable analysis lessons learned and established best practices for future design cycles. However, the Cycle 3 design did include some major liens and evolving requirements which were addressed in the Cycle 4 Design. Some of the design changes are driven by requirements changes, while others are optimizations or solutions to liens from previous cycles. Again in Cycle 4, STOP analysis was performed and further insights into the overall design were gained leading to the Cycle 5 design effort currently underway. This paper seeks to capture the thermal design evolution, with focus on major design drivers, key decisions and their rationale, and lessons learned as the design evolved.

Thermal Design↗

NASA NTRS2015

Design Evolution of the Wide Field Infrared Survey Telescope Using Astrophysics Focused Telescope Assets (WFIRST-AFTA) and Lessons Learned

The design of the Wide Field Infrared Survey Telescope using Astrophysics Focused Telescope Assets (WFIRST-AFTA) continues to evolve as each design cycle is analyzed. In 2012, two Hubble sized (2.4 m diameter) telescopes were donated to NASA from elsewhere in the Federal Government. NASA began investigating potential uses for these telescopes and identified WFIRST as a mission to benefit from these assets. With an updated, deeper, and sharper field of view than previous design iterations with a smaller telescope, the optical designs of the WFIRST instruments were updated and the mechanical and thermal designs evolved around the new optical layout. Beginning with Design Cycle 3, significant analysis efforts yielded a design and model that could be evaluated for Structural-Thermal-Optical-Performance (STOP) purposes for the Wide Field Imager (WFI) and provided the basis for evaluating the high level observatory requirements. Development of the Cycle 3 thermal model provided some valuable analysis lessons learned and established best practices for future design cycles. However, the Cycle 3 design did include some major liens and evolving requirements which were addressed in the Cycle 4 Design. Some of the design changes are driven by requirements changes, while others are optimizations or solutions to liens from previous cycles. Again in Cycle 4, STOP analysis was performed and further insights into the overall design were gained leading to the Cycle 5 design effort currently underway. This paper seeks to capture the thermal design evolution, with focus on major design drivers, key decisions and their rationale, and lessons learned as the design evolved.

WFIRST↗

NASA NTRS2014

Lessons Learned in the First Year Operating Software Defined Radios in Space

Operating three unique software defined radios (SDRs) in a space environment aboard the Space Communications and Navigation (SCaN) Testbed for over one year has provided an opportunity to gather knowledge useful for future missions considering using software defined radios. This paper provides recommendations for the development and use of SDRs, and it considers the details of each SDR's approach to software upgrades and operation. After one year, the SCaN Testbed SDRs have operated for over 1000 hours. During this time, the waveforms launched with the SDR were tested on-orbit to assure that they operated in space at the same performance level as on the ground prior to launch to obtain an initial on-orbit performance baseline. A new waveform for each SDR has been developed, implemented, uploaded to the flight system, and tested in the flight environment. Recommendations for SDR-based missions have been gathered from early development through operations. These recommendations will aid future missions to reduce the cost, schedule, and risk of operating SDRs in a space environment. This paper considers the lessons learned as they apply to SDR pre-launch checkout, purchasing space-rated hardware, flexibility in command and telemetry methods, on-orbit diagnostics, use of engineering models to aid future development, and third-party software. Each SDR implements the SCaN Testbed flight computer command and telemetry interface uniquely, allowing comparisons to be drawn. The paper discusses the lessons learned from these three unique implementations, with suggestions on the preferred approach. Also, results are presented showing that it is important to have full system performance knowledge prior to launch to establish better performance baselines in space, requiring additional test applications to be developed pre-launch. Finally, the paper presents the issues encountered with the operation and implementation of new waveforms on each SDR and proposes recommendations to avoid these issues.

space communication↗

NASA NTRS2023

SERFE PLSS Component Lessons Learned from ISS

NASA has been developing a new spacesuit, called the Exploration Extravehicular Mobility Unit (xEMU) for over a decade. This spacesuit is under development to support missions to the International Space Station (ISS) and also to the Moon. Improvements in the life and robustness of the Portable Life Support System (PLSS) has been a major objective of these efforts. The Suit Water Membrane Evaporator (SWME) was chosen as the technology to provide cooling to the xEMU and has undergone several iterations of development over this period. An ISS flight experiment centered around the SWME and other thermal control loop (TCL) technologies was developed and tested in an ISS EXpedite PRocessing of Experiments to the Space Station (EXPRESS) rack from November of 2020 to August of 2022. In addition to the SWME, the SWME EXPRESS Rack Flight Experiment (SERFE) contains several technologies from the xEMU project and demonstrated their performance in micro-gravity and over an extended duration. These included two dissimilar water pumps, custom check valves, custom bypass relieve valves, a custom thermal control valve, development pressure and temperature sensors, and the thermal loop controller. This paper presents PLSS component lessons learned after return of the SERFE flight unit in August of 2022. The SERFE team took the flight unit apart and handed hardware components over to hardware owners to see how parts of the TCL managed after almost 2 years on the ISS and 25 simulated EVAs (Exploration Extravehicular Activity) on orbit. The team performed inspection, testing, and analysis and provided lessons learned on PLSS components for NASA’s prototype spacesuit. This analysis included how well SWME maintained its heat rejection capability, as well as looked at the robustness of the other TCL hardware.

SERFE↗

NASA NTRS2023

SERFE PLSS Component Lessons Learned from ISS

NASA has been developing a new spacesuit, called the Exploration Extravehicular Mobility Unit (xEMU) for over a decade. This spacesuit is under development to support missions to the International Space Station (ISS) and also to the Moon. Improvements in the life and robustness of the Portable Life Support System (PLSS) has been a major objective of these efforts. The Suit Water Membrane Evaporator (SWME) was chosen as the technology to provide cooling to the xEMU and has undergone several iterations of development over this period. An ISS flight experiment centered around the SWME and other thermal control loop (TCL) technologies was developed and tested in an ISS EXpedite PRocessing of Experiments to the Space Station (EXPRESS) rack from November of 2020 to August of 2022. In addition to the SWME, the SWME EXPRESS Rack Flight Experiment (SERFE) contains several technologies from the xEMU project and demonstrated their performance in micro-gravity and over an extended duration. These included two dissimilar water pumps, custom check valves, custom bypass relieve valves, a custom thermal control valve, development pressure and temperature sensors, and the thermal loop controller. This paper presents PLSS component lessons learned after return of the SERFE flight unit in August of 2022. The SERFE team took the flight unit apart and handed hardware components over to hardware owners to see how parts of the TCL managed after almost 2 years on the ISS and 25 simulated EVAs (Exploration Extravehicular Activity) on orbit. The team performed inspection, testing, and analysis and provided lessons learned on PLSS components for NASA’s prototype spacesuit. This analysis included how well SWME maintained its heat rejection capability, as well as looked at the robustness of the other TCL hardware.

SERFE↗

NASA NTRS2001

Lessons Learned from Real-Time, Event-Based Internet Science Communications

For the last several years the Science Directorate at Marshall Space Flight Center has carried out a diverse program of Internet-based science communication. The Directorate's Science Roundtable includes active researchers, NASA public relations, educators, and administrators. The Science@NASA award-winning family of Web sites features science, mathematics, and space news. The program includes extended stories about NASA science, a curriculum resource for teachers tied to national education standards, on-line activities for students, and webcasts of real-time events. The focus of sharing science activities in real-time has been to involve and excite students and the public about science. Events have involved meteor showers, solar eclipses, natural very low frequency radio emissions, and amateur balloon flights. In some cases, broadcasts accommodate active feedback and questions from Internet participants. Through these projects a pattern has emerged in the level of interest or popularity with the public. The pattern differentiates projects that include science from those that do not, All real-time, event-based Internet activities have captured public interest at a level not achieved through science stories or educator resource material exclusively. The worst event-based activity attracted more interest than the best written science story. One truly rewarding lesson learned through these projects is that the public recognizes the importance and excitement of being part of scientific discovery. Flying a camera to 100,000 feet altitude isn't as interesting to the public as searching for viable life-forms at these oxygen-poor altitudes. The details of these real-time, event-based projects and lessons learned will be discussed.

Phillips, T.↗

NASA NTRS1986

Some lessons learned with wind tunnels

A review is presented of some of the lessons learned from wind tunnel tests since World War II. Wind tunnels achieved a very high productivity rate during the war due in part to development testing of numerous military aircraft concepts. Following the war, in addition to development testing, a rapid increase in basic research testing occurred in order to explore areas of interest revealed by the conduct of war and to expand on advanced technology that became available from Germany and Italy. The research test areas discussed are those primarily related to the transition from subsonic flight to supersonic flight.

Spearman, M. L.↗

NASA NTRS1986

Lessons learned: Managing the development of a corporate Ada training project

The management lessons learned during the implementation of a corporate mandate to develop and deliver an effective Ada training program to all divisions are discussed. The management process involved in obtaining cooperation from all levels in the development of a corporate-wide project is described. The problem areas are identified along with some possible solutions.

Blackmon, Linda F.↗

NASA NTRS2014

Veggie Hardware Validation Test Preliminary Results and Lessons Learned

The Veggie hardware validation test, VEG-01, was conducted on the International Space Station during Expeditions 39 and 40 from May through June of 2014. The Veggie hardware and the VEG-01 experiment payload were launched to station aboard the SpaceX-3 resupply mission in April, 2014. Veggie was installed in an Expedite-the-Processing-of-Experiments-to-Space-Station (ExPRESS) rack in the Columbus module, and the VEG-01 validation test was initiated. Veggie installation was successful, and power was supplied to the unit. The hardware was programmed and the root mat reservoir and plant pillows were installed without issue. As expected, a small amount of growth media was observed in the sealed bags which enclosed the plant pillows when they were destowed. Astronaut Steve Swanson used the wet/dry vacuum to clean up the escaped particles. Water insertion or priming the first plant pillow was unsuccessful as an issue prevented water movement through the quick disconnect. All subsequent pillows were successfully primed, and the initial pillow was replaced with a backup pillow and successfully primed. Six pillows were primed, but only five pillows had plants which germinated. After about a week and a half it was observed that plants were not growing well and that pillow wicks were dry. This indicated that the reservoir was not supplying sufficient water to the pillows via wicking, and so the team reverted to an operational fix which added water directly to the plant pillows. Direct watering of the pillows led to a recovery in several of the stressed plants; a couple of which did not recover. An important lesson learned involved Veggie's bellows. The bellows tended to float and interfere with operations when opened, so Steve secured them to the baseplate during plant tending operations. Due to the perceived intensity of the LED lights, the crew found it challenging to both work under the lights and read crew procedures on their computer. Although the lights are not a safety hazard, for visual comfort crewmembers were advised to wear sunglasses when working with the plants and then they can lift glasses to read procedures. Steve Swanson had already trail-blazed this procedure when he initiated VEG-01. The temperature and humidity data logger was relocated mid-experiment to provide measurements on both sides of the unit. Images of the plants were downlinked weekly, and videos of installation and harvest were recorded. This imaging frequency was not sufficient to monitor and respond to changes in plant growth. Plants, samples, and data loggers will be returned on SpaceX-4, scheduled to return the fall of 2014. Lessons learned will be translated into hardware and operational modifications for future Veggie payloads.

International Space Station↗

NASA NTRS2018

Gary Johnson: Lessons Learned from 50+ Years in Human Spaceflight and Safety

Future spacecraft designers and managers need to be aware of problems, corrective actions, and the resulting lessons learned to avoid experiencing the same problems in new programs. Fewer and fewer people with firsthand experience of the design, test, and operations of past programs, such as Apollo, are available today to pass on their experience. This white paper, sponsored by the Johnson Space Center (JSC) Safety and Mission Assurance (SMA) Directorate Flight Safety Office (FSO), will discuss the major lessons I learned during my 50+ years (and counting) working in human spaceflight.

Johnson, Gary W.↗

NASA NTRS1976

Skylab lessons learned as applicable to a large space station, 1967-1974

This report records some of the lessons learned during Skylab development. The approach taken is to list lessons which could have wide application in the development of a large space station. The lessons are amplified and explained in light of the background and experiences of the Skylab development.

Schneider, W. C.↗

NASA NTRSDate not supplied

A Frank Discussion on Lessons Learned From Adopting and Applying NASA-STD-6030 for Spaceflight Systems

With the advancement and adoption of Additive Manufacturing (AM) for spaceflight systems, numerous lessons have been learned during the qualification and certification of AM components. The lessons learned covered in this presentation will provide an overview of the challenges faced by NASA centers and commercial partners working to design AM hardware that complies with NASA-STD-6030 Additive Manufacturing Requirements (AMR). Topics of interest include tailoring of requirements for specific projects, documentation requirements, and addressing conservative approaches towards mechanical property development and analysis. In addition to that, this presentation aims to impress that these lessons learned will influence the future revisions of the NASA technical standard to facilitate and advance AM technology adoption on NASA projects.

Additive Manufacturing↗