Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Assembly and Manufacturing”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

An Update on the Development of a Line-Focus Refractive Concentrator Array

Concentrator arrays offer a number of generic benefits for space (i.e. high array efficiency, protection from space radiation effects, minimized plasma interactions, etc.). The line-focus refractive concentrator concept, however, also offers two very important advantages: (1) relaxation of precise array tracking requirements to only a single axis and (2) low-cost mass production of the lens material. The linear refractive concentrator can be designed to provide an essentially flat response over a wide range of longitudinal errors for satellites having only single-axis tracking capability. New panel designs emphasize light weight, high stiffness, stowability and ease of manufacturing and assembly. This paper will address the current status of the concentrator program with special emphasis on the design implications, and flexibility, of using a linear refractive concentrator lens as well as detail the recent fabrication of prototype hardware.

Piszczor, Michael F.↗
NASA NTRS2000

Design Study for A Low-Cost LH2 Turbopump

A preliminary design study, focusing on potential component selections and design for manufacturing and assembly (DFMAR1) analysis, is presented in this study. The investigation focused on a nominal cost liquid hydrogen turbopump suitable for a private launch class vehicle. Utilizing a "turbocharger-like" design philosophy, preliminary feasibility studies of the basic pump design class, the rotordynamic design class, and the turbine design class were conducted with associated DFMA evaluations. Reasonable cost levels and sensible levels of product assurance have been established.

Japikse, David↗
NASA NTRS2001

Modeling, Modal Properties, and Mesh Stiffness Variation Instabilities of Planetary Gears

Planetary gear noise and vibration are primary concerns in their applications in helicopters, automobiles, aircraft engines, heavy machinery and marine vehicles. Dynamic analysis is essential to the noise and vibration reduction. This work analytically investigates some critical issues and advances the understanding of planetary gear dynamics. A lumped-parameter model is built for the dynamic analysis of general planetary gears. The unique properties of the natural frequency spectra and vibration modes are rigorously characterized. These special structures apply for general planetary gears with cyclic symmetry and, in practically important case, systems with diametrically opposed planets. The special vibration properties are useful for subsequent research. Taking advantage of the derived modal properties, the natural frequency and vibration mode sensitivities to design parameters are investigated. The key parameters include mesh stiffnesses, support/bearing stiffnesses, component masses, moments of inertia, and operating speed. The eigen-sensitivities are expressed in simple, closed-form formulae associated with modal strain and kinetic energies. As disorders (e.g., mesh stiffness variation. manufacturing and assembling errors) disturb the cyclic symmetry of planetary gears, their effects on the free vibration properties are quantitatively examined. Well-defined veering rules are derived to identify dramatic changes of natural frequencies and vibration modes under parameter variations. The knowledge of free vibration properties, eigen-sensitivities, and veering rules provide important information to effectively tune the natural frequencies and optimize structural design to minimize noise and vibration. Parametric instabilities excited by mesh stiffness variations are analytically studied for multi-mesh gear systems. The discrepancies of previous studies on parametric instability of two-stage gear chains are clarified using perturbation and numerical methods. The operating conditions causing parametric instabilities are expressed in closed-form suitable for design guidance. Using the well-defined modal properties of planetary gears, the effects of mesh parameters on parametric instability are analytically identified. Simple formulae are obtained to suppress particular instabilities by adjusting contact ratios and mesh phasing.

Parker, Robert G.↗
NASA NTRS2001

A Magnetoresistive Heat Switch for the Continuous ADR

In compensated elemental metals at low temperature, a several Tesla field can suppress electronic heat conduction so thoroughly that heat is effectively carried by phonons alone. In approximately one mm diameter single crystal samples with impurity concentrations low enough that electron conduction is limited by surface scattering, the ratio of zerofield to high-field thermal conductivity can exceed ten thousand. We have used this phenomenon to build a compact, solid-state heat switch with no moving parts and no enclosed fluids. The time scale for switching states is limited by time scale for charging the magnet that supplies the controlling field. Our design and fabrication techniques overcome the difficulties associated with manufacturing and assembling parts from single crystal tungsten. A clear disadvantage of the magnetoresistive switch is the mass and complexity of the magnet system for the controlling field. We have discovered a technique of minimizing this mass and complexity, applicable to the continuous adiabatic demagnetization refrigerator.

Canavan, E. R.↗
NASA NTRS2004

An Educational Multimedia Presentation on the Introduction to Spacecraft Charging

Over the last few decades, significant knowledge has been gained in how to protect spacecraft from charging; however, the continuing technical advancement in the design and build of satellites requires on-going effort in the study of spacecraft charging. A situation that we have encountered is that not all satellite designers and builders are familiar with the problem of spacecraft charging. The design of a satellite involves many talented people with diverse backgrounds, ranging from manufacturing and assembly to engineering and program management. The complex design and build of a satellite system requires people with highly specialized skills such that cross-specialization is often not achievable. As a result, designers and builders of satellites are not usually familiar with the problems outside their specialization. This is also true for spacecraft charging. Not everyone is familiar with the definition of spacecraft charging and the damage that spacecraft charging can cause. Understanding the problem is an important first step in getting everyone involved in addressing the appropriate spacecraft charging issues during the satellite design and build phases. To address this important first step, an educational multimedia presentation has been created to inform the general engineering community about the basics of spacecraft charging. The content of this educational presentation is based on relevant published technical papers. The presentation was developed using Macromedia Flash. This software produces a more dynamic learning environment than a typical slide show , resulting in a more effective learning experience. The end result is that the viewer will have learned about the basics of spacecraft charging. This presentation is available to the public through our website, www.dplscience.com, free of charge. Viewers are encouraged to pass this presentation to colleagues within their own work environment. This paper describes the content of the multimedia presentation.

Lin, E.↗
NASA NTRS2005

Putting EVM to the Test

IN MANY INSTANCES THERE IS NO FOREWARNING; SCHEDULES slip, costs soar, and the project manager is faced with the near impossible task of explaining why each impact occurred. With contractors performing the majority of the work, the management job can become even more obscure. The simple lack of proximity to the contractor can limit effective communication. Add to that a mixture of cultural differences and a desire for the contractor to portray the most optimistic view of their performance, and you create an even more difficult task for the project manager. This was the scenario when the Habitat Holding Rack (HHR) manager at Marshall Space Flight Center (MSFC), Stacy Counts, was introduced to the overall concept of Earned Value Management (EVM). Faced with increased costs (which eventually resulted in decreased scope of the project), continued schedule slides, and several technical anomalies, she was looking for a way to gain a better handle on the project performance. As a component of the Space Station Biological Research Program (SSBRP), the HHR project is an integral piece of the Program content. The HHR is the first rack hardware to be delivered for the Program and has therefore been the first rack to move through the trials of test and verification-documenting anomalies and technical difficulties that will benefit the other SSBRP rack projects. For these reasons, the HHR maintained high visibility throughout the manufacturing and assembly process, continuing through test and verification activities. Needless to say, the higher visibility emphasized the need for improved performance on this project. And to improve project performance, Stacy first had to figure out how to measure the cost, schedule and technical objectives effectively.

Kerby, Jerald↗
NASA NTRS2005

Return to Flight Resource Reel 2 of 2

A continuation of the tests performed on the Space Shuttle Discovery in preparation for its return to flight is presented. The tests include: 1) Shuttle Robot Arm Recertification; 2) Michael Hiltz Systems Group Leader; 3) Orbiter Boom Fabrication; 4) Orbiter Boom Final Development; 5) Gary Searle Manager of Orbiter Boom Sensor System (OBSS) Manufacturing and Assembly; 6) Orbiter Boom Qualification Unit; 7) STS-114 Crew Inspects Orbiter Boom at Kennedy Space Center; 8) Orbiter Boom Inspection of Thermal Protection System Animation; 9) External Tank Bipod Redesign; 10) External Tank Flange Redesign; 11) External Tank Bellows Redesign; 12) Shuttle Main Engine Testing and Delivery to Kennedy Space Center; 13) Ronnie Rigney Project Manager Space Shuttle Main Engine Program Office; 14) Gene Goldmman NASA Project Manager Space Shuttle Main Engine Project; 15) Mike Cosgrove Boeing-Rocketdyne Flow Manager; 16) Shuttle Rocket Booster Build-Up; 17) Ascent Imagery Improvements; and 18) STS-114 Flight Control Team and Mission Management Team.

Source record↗
NASA NTRS2005

CRYOGENIC UPPER STAGE SYSTEM SAFETY

NASA s Exploration Initiative will require development of many new systems or systems of systems. One specific example is that safe, affordable, and reliable upper stage systems to place cargo and crew in stable low earth orbit are urgently required. In this paper, we examine the failure history of previous upper stages with liquid oxygen (LOX)/liquid hydrogen (LH2) propulsion systems. Launch data from 1964 until midyear 2005 are analyzed and presented. This data analysis covers upper stage systems from the Ariane, Centaur, H-IIA, Saturn, and Atlas in addition to other vehicles. Upper stage propulsion system elements have the highest impact on reliability. This paper discusses failure occurrence in all aspects of the operational phases (Le., initial burn, coast, restarts, and trends in failure rates over time). In an effort to understand the likelihood of future failures in flight, we present timelines of engine system failures relevant to initial flight histories. Some evidence suggests that propulsion system failures as a result of design problems occur shortly after initial development of the propulsion system; whereas failures because of manufacturing or assembly processing errors may occur during any phase of the system builds process, This paper also explores the detectability of historical failures. Observations from this review are used to ascertain the potential for increased upper stage reliability given investments in integrated system health management. Based on a clear understanding of the failure and success history of previous efforts by multiple space hardware development groups, the paper will investigate potential improvements that can be realized through application of system safety principles.

Smith, R. Kenneth↗
NASA NTRS2009

Advanced Development Program for a 625 lbf thrust engine for Ares First Stage Roll Control System

NASA's new Ares Launch Vehicle will require twelve thrusters to provide roll control of the vehicle during the first stage firing. All twelve roll control thrusters will be located at the inter-stage segment that separates the solid rocket booster first stage from the second stage. NASA selected a mono propellant hydrazine solution and as a result awarded Aerojet-General a contract in 2007 for an advanced development program for an MR-80- series 625 Ibf vacuum thrust monopropellant hydrazine thruster. This thruster has heritage dating back to the 1976 Viking Landers and most recently for the 2011 Mars Science Laboratory. Prior to the Ares application, the MR-80-series thrusters had been equipped with throttle valves and not typically operated in pulse mode. The primary objective of the advanced development program was to increase the technology readiness level and retire major technical risks for the future flight qualification test program. Aerojet built on their heritage MR-80 rocket engine designs to achieve the design and performance requirements. Significant improvements to cost and lead-time were achieved by applying Design for Manufacturing and Assembly (DFMA) principles. AerojetGeneral has completed Preliminary and Critical Design Reviews, followed by two successful rocket engine development test programs. The test programs included qualification random vibration and firing lite that significantly exceed the flight qualification requirements. This paper discusses the advanced development program and the demonstrated capability of the MR-80C engine. Y;

Dawson, Matt↗
NASA NTRS2010

Design Considerations for Human Rating of Liquid Rocket Engines

I.Human-rating is specific to each engine; a. Context of program/project must be understood. b. Engine cannot be discussed independently from vehicle and mission. II. Utilize a logical combination of design, manufacturing, and test approaches a. Design 1) It is crucial to know the potential ways a system can fail, and how a failure can propagate; 2) Fault avoidance, fault tolerance, DFMR, caution and warning all have roles to play. b. Manufacturing and Assembly; 1) As-built vs. as-designed; 2) Review procedures for assembly and maintenance periodically; and 3) Keep personnel trained and certified. c. There is no substitute for test: 1) Analytical tools are constantly advancing, but still need test data for anchoring assumptions; 2) Demonstrate robustness and explore sensitivities; 3) Ideally, flight will be encompassed by ground test experience. III. Consistency and repeatability is key in production a. Maintain robust processes and procedures for inspection and quality control based upon development and qualification experience; b. Establish methods to "spot check" quality and consistency in parts: 1) Dedicated ground test engines; 2) Random components pulled from the line/lot to go through "enhanced" testing.

Parkinson, Douglas↗
NASA NTRS2009

Modeling and Simulation at NASA

This slide presentation is composed of two topics. The first reviews the use of modeling and simulation (M&S) particularly as it relates to the Constellation program and discrete event simulation (DES). DES is defined as a process and system analysis, through time-based and resource constrained probabilistic simulation models, that provide insight into operation system performance. The DES shows that the cycles for a launch from manufacturing and assembly to launch and recovery is about 45 days and that approximately 4 launches per year are practicable. The second topic reviews a NASA Standard for Modeling and Simulation. The Columbia Accident Investigation Board made some recommendations related to models and simulations. Some of the ideas inherent in the new standard are the documentation of M&S activities, an assessment of the credibility, and reporting to decision makers, which should include the analysis of the results, a statement as to the uncertainty in the results,and the credibility of the results. There is also discussion about verification and validation (V&V) of models. There is also discussion about the different types of models and simulation.

Steele, Martin J.↗
NASA NTRS2010

Constraint and Flight Rule Management for Space Mission Operations

The exploration of space is one of the most fascinating domains to study from a human factors perspective. Like other complex work domains such as aviation (Pritchett and Kim, 2008), air traffic management (Durso and Manning, 2008), health care (Morrow, North, and Wickens, 2006), homeland security (Cooke and Winner, 2008), and vehicle control (Lee, 2006), space exploration is a large-scale sociotechnical work domain characterized by complexity, dynamism, uncertainty, and risk in real-time operational contexts (Perrow, 1999; Woods et al, 1994). Nearly the entire gamut of human factors issues - for example, human-automation interaction (Sheridan and Parasuraman, 2006), telerobotics, display and control design (Smith, Bennett, and Stone, 2006), usability, anthropometry (Chaffin, 2008), biomechanics (Marras and Radwin, 2006), safety engineering, emergency operations, maintenance human factors, situation awareness (Tenney and Pew, 2006), crew resource management (Salas et al., 2006), methods for cognitive work analysis (Bisantz and Roth, 2008) and the like -- are applicable to astronauts, mission control, operational medicine, Space Shuttle manufacturing and assembly operations, and space suit designers as they are in other work domains (e.g., Bloomberg, 2003; Bos et al, 2006; Brooks and Ince, 1992; Casler and Cook, 1999; Jones, 1994; McCurdy et al, 2006; Neerincx et aI., 2006; Olofinboba and Dorneich, 2005; Patterson, Watts-Perotti and Woods, 1999; Patterson and Woods, 2001; Seagull et ai, 2007; Sierhuis, Clancey and Sims, 2002). The human exploration of space also has unique challenges of particular interest to human factors research and practice. This chapter provides an overview of those issues and reports on some of the latest research results as well as the latest challenges still facing the field.

Barreiro, J.↗
NASA NTRS2010

Human Factors in Space Exploration

The exploration of space is one of the most fascinating domains to study from a human factors perspective. Like other complex work domains such as aviation (Pritchett and Kim, 2008), air traffic management (Durso and Manning, 2008), health care (Morrow, North, and Wickens, 2006), homeland security (Cooke and Winner, 2008), and vehicle control (Lee, 2006), space exploration is a large-scale sociotechnical work domain characterized by complexity, dynamism, uncertainty, and risk in real-time operational contexts (Perrow, 1999; Woods et ai, 1994). Nearly the entire gamut of human factors issues - for example, human-automation interaction (Sheridan and Parasuraman, 2006), telerobotics, display and control design (Smith, Bennett, and Stone, 2006), usability, anthropometry (Chaffin, 2008), biomechanics (Marras and Radwin, 2006), safety engineering, emergency operations, maintenance human factors, situation awareness (Tenney and Pew, 2006), crew resource management (Salas et aI., 2006), methods for cognitive work analysis (Bisantz and Roth, 2008) and the like -- are applicable to astronauts, mission control, operational medicine, Space Shuttle manufacturing and assembly operations, and space suit designers as they are in other work domains (e.g., Bloomberg, 2003; Bos et al, 2006; Brooks and Ince, 1992; Casler and Cook, 1999; Jones, 1994; McCurdy et ai, 2006; Neerincx et aI., 2006; Olofinboba and Dorneich, 2005; Patterson, Watts-Perotti and Woods, 1999; Patterson and Woods, 2001; Seagull et ai, 2007; Sierhuis, Clancey and Sims, 2002). The human exploration of space also has unique challenges of particular interest to human factors research and practice. This chapter provides an overview of those issues and reports on sorne of the latest research results as well as the latest challenges still facing the field.

FROM↗
NASA NTRS2012

External Surface Changes Observed on the International Space Station (ISS) Through 2012

As the International Space Station (ISS) surpasses 13 years of on-orbit operation, 11 of those years continuously inhabited, external surfaces of the vehicle have shown a wide variety of visible environmental effects. Throughout, the ISS program has maintained a significant effort to routinely document the vehicle external surface condition and to monitor those changes with time. The impacts of micrometeoroids and orbital debris, surface changes from molecular contamination of various sources, and the effects of ultraviolet radiation and atomic oxygen have all been noted. The tremendous size and complexity of the ISS vehicle has yielded a wide variety of observations of interest to the spacecraft materials engineer concerning long-term, low earth orbit (LEO) space environmental effects (SEE). In addition, inadvertent materials substitutions have been identified because of these environmental effects, as well as inadequate contamination control practices likely occurring during hardware manufacture and assembly. Some of the observations from our photography are purely artifacts of the unusual lighting conditions and environments that exist in space. A compilation of ISS on-orbit photography representing all of these aspects is presented, demonstrating the various SEE and their impacts as a function of time in LEO, including interpretations of those effects.

Golden, Johnny L.↗
NASA NTRS2015

Development of Additive Construction Technologies for Application to Development of Lunar/Martian Surface Structures Using In-Situ Materials

For long-duration missions on other planetary bodies, the use of in situ materials will become increasingly critical. As human presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for the self-sufficiency and sustainability necessary for long-duration habitation. Previously, under the auspices of the MSFC In-Situ Fabrication and Repair (ISFR) project and more recently, under the jointly-managed MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in-situ resources. One such additive construction technology is known as Contour Crafting. This paper presents the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using this process. Conceived initially for rapid development of cementitious structures on Earth, it also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and binders developed from in situ materials as well. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. Future planned activities will be discussed as well.

Werkheiser, Niki J.↗
NASA NTRS2015

On The Development of Additive Construction Technologies for Application to Development of Lunar/Martian Surface Structures Using In-Situ Materials

For long-duration missions on other planetary bodies, the use of in-situ materials will become increasingly critical. As man's presence on these bodies expands, so must the breadth of the structures required to accommodate them including habitats, laboratories, berms, radiation shielding for natural radiation and surface reactors, garages, solar storm shelters, greenhouses, etc. Planetary surface structure manufacturing and assembly technologies that incorporate in-situ resources provide options for autonomous, affordable, pre-positioned environments with radiation shielding features and protection from micrometeorites, exhaust plume debris, and other hazards. This is important because gamma and particle radiation constitute a serious but reducible threat to long-term survival of human beings, electronics, and other materials in space environments. Also, it is anticipated that surface structures will constitute the primary mass element of lunar or Martian launch requirements. The ability to use in-situ materials to construct these structures will provide a benefit in the reduction of up-mass that would otherwise make long-term Moon or Mars structures cost prohibitive. The ability to fabricate structures in situ brings with it the ability to repair these structures, which allows for self-sufficiency necessary for long-duration habitation. Previously, under the auspices of the MSFC In Situ Fabrication and Repair (ISFR) project and more recently, under the joint MSFC/KSC Additive Construction with Mobile Emplacement (ACME) project, the MSFC Surface Structures Group has been developing materials and construction technologies to support future planetary habitats with in situ resources. One such technology, known as Contour Crafting (additive construction), is shown in Figure 1, along with a typical structure fabricated using this technology. This paper will present the results to date of these efforts, including development of novel nozzle concepts for advanced layer deposition using the Contour Crafting process. This process, conceived initially for rapid development of cementitious structures on Earth, also lends itself exceptionally well to the automated fabrication of planetary surface structures using minimally processed regolith as aggregate, and imported binder material or binders developed from in situ materials. This process has been used successfully in the fabrication of construction elements using lunar regolith simulant and Mars regolith simulant, both with various binder materials. These binder materials have resulted from extensive evaluation and include both "imported" binder materials that might be launched from Earth as well as some binder materials that can theoretically also be derived from existing regolith materials. They were chosen to 1) reduce penetrating radiation as much as possible, primarily with hydrogen-bearing polymers, 2) attempt to provide an air-tight structure, 3) sufficiently mix and adsorb to regolith grains for strength, 4) maximize tolerance to day-night thermal cycling, 5) possibly increase electrical conductivity to dissipate any accumulated static charge, and 6) ease their application on planetary surfaces (specifically, the accommodation of reduced atmosphere and lack of heat sinks). Some of these materials have been tested with respect to radiation mitigation, micrometeorite resistance, and resistance to larger, slower-traveling pieces of regolith impinging on the surface, simulating nearby launch and landing activities. Conceptual designs for a Continuous Feedstock Delivery/Mixing System (CFDMS) will also be presented and future planned activities will be discussed as well.

Werkheiser, Niki↗
NASA NTRS2016

Pitfalls and Precautions When Using Predicted Failure Data for Quantitative Analysis of Safety Risk for Human Rated Launch Vehicles

Launch vehicle reliability analysis is largely dependent upon using predicted failure rates from data sources such as MIL-HDBK-217F. Reliability prediction methodologies based on component data do not take into account system integration risks such as those attributable to manufacturing and assembly. These sources often dominate component level risk. While consequence of failure is often understood, using predicted values in a risk model to estimate the probability of occurrence may underestimate the actual risk. Managers and decision makers use the probability of occurrence to influence the determination whether to accept the risk or require a design modification. The actual risk threshold for acceptance may not be fully understood due to the absence of system level test data or operational data. This paper will establish a method and approach to identify the pitfalls and precautions of accepting risk based solely upon predicted failure data. This approach will provide a set of guidelines that may be useful to arrive at a more realistic quantification of risk prior to acceptance by a program.

Hatfield, Glen S.↗
NASA NTRS2015

Ames Modular Common Spacecraft Bus

The Ames Modular Common Spacecraft Bus is a lightweight carbon composite structure designed to accommodate launch loads and provide attenuation of impact loads. It is also designed for ease of manufacturing and assembly. The modularity of the design is intended not only for multiple mission configurations,but also parallelism in development and assembly. The system-level components were drawn from low-cost flight-proven product lines.

Common bus↗