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NASA NTRS2012

Flexible Plug Repair for Shuttle Wing Leading Edge

In response to the Columbia Accident Investigation Board report, a plug repair kit has been developed to enable astronauts to repair the space shuttle's wing leading edge (WLE) during orbit. The plug repair kit consists of several 17.78- cm-diameter carbon/silicon carbide (C/SiC) cover plates of various curvatures that can be attached to the refractory carbon-carbon WLE panels using a TZM refractory metal attach mechanism. The attach mechanism is inserted through the damage in the WLE panel and, as it is tightened, the cover plate flexes to conform to the curvature of the WLE panel within 0.050 mm. An astronaut installs the repair during an extravehicular activity (EVA). After installing the plug repair, edge gaps are checked and the perimeter of the repair is sealed using a proprietary material, developed to fill cracks and small holes in the WLE.

Camarda, Charles J.↗

NASA NTRS2012

SpaceCube Mini

This version of the SpaceCube will be a full-fledged, onboard space processing system capable of 2500+ MIPS, and featuring a number of plug-andplay gigabit and standard interfaces, all in a condensed 3x3x3 form factor [less than 10 watts and less than 3 lb (approximately equal to 1.4 kg)]. The main processing engine is the Xilinx SIRF radiation- hardened-by-design Virtex-5 FX-130T field-programmable gate array (FPGA). Even as the SpaceCube 2.0 version (currently under test) is being targeted as the platform of choice for a number of the upcoming Earth Science Decadal Survey missions, GSFC has been contacted by customers who wish to see a system that incorporates key features of the version 2.0 architecture in an even smaller form factor. In order to fulfill that need, the SpaceCube Mini is being designed, and will be a very compact and low-power system. A similar flight system with this combination of small size, low power, low cost, adaptability, and extremely high processing power does not otherwise exist, and the SpaceCube Mini will be of tremendous benefit to GSFC and its partners. The SpaceCube Mini will utilize space-grade components. The primary processing engine of the Mini is the Xilinx Virtex-5 SIRF FX-130T radiation-hardened-by-design FPGA for critical flight applications in high-radiation environments. The Mini can also be equipped with a commercial Xilinx Virtex-5 FPGA with integrated PowerPCs for a low-cost, high-power computing platform for use in the relatively radiation- benign LEOs (low-Earth orbits). In either case, this version of the Space-Cube will weigh less than 3 pounds (.1.4 kg), conform to the CubeSat form-factor (10x10x10 cm), and will be low power (less than 10 watts for typical applications). The SpaceCube Mini will have a radiation-hardened Aeroflex FPGA for configuring and scrubbing the Xilinx FPGA by utilizing the onboard FLASH memory to store the configuration files. The FLASH memory will also be used for storing algorithm and application code for the PowerPCs and the Xilinx FPGA. In addition, it will feature highspeed DDR SDRAM (double data rate synchronous dynamic random-access memory) to store the instructions and data of active applications. This version will also feature SATA-II and Gigabit Ethernet interfaces. Furthermore, there will also be general-purpose, multi-gigabit interfaces. In addition, the system will have dozens of transceivers that can support LVDS (low-voltage differential signaling), RS-422, or SpaceWire. The SpaceCube Mini includes an I/O card that can be customized to meet the needs of each mission. This version of the SpaceCube will be designed so that multiple Minis can be networked together using SpaceWire, Ethernet, or even a custom protocol. Scalability can be provided by networking multiple SpaceCube Minis together. Rigid-Flex technology is being targeted for the construction of the SpaceCube Mini, which will make the extremely compact and low-weight design feasible. The SpaceCube Mini is designed to fit in the compact CubeSat form factor, thus allowing deployment in a new class of missions that the previous SpaceCube versions were not suited for. At the time of this reporting, engineering units should be available in the summer 2012.

Michael Lin↗

NASA NTRS2012

Mars Science Laboratory Drill

This drill (see Figure 1) is the primary sample acquisition element of the Mars Science Laboratory (MSL) that collects powdered samples from various types of rock (from clays to massive basalts) at depths up to 50 mm below the surface. A rotary-percussive sample acquisition device was developed with an emphasis on toughness and robustness to handle the harsh environment on Mars. It is the first rover-based sample acquisition device to be flight-qualified (see Figure 2). This drill features an autonomous tool change-out on a mobile robot, and novel voice-coil-based percussion. The drill comprises seven subelements. Starting at the end of the drill, there is a bit assembly that cuts the rock and collects the sample. Supporting the bit is a subassembly comprising a chuck mechanism to engage and release the new and worn bits, respectively, and a spindle mechanism to rotate the bit. Just aft of that is a percussion mechanism, which generates hammer blows to break the rock and create the dynamic environment used to flow the powdered sample. These components are mounted to a translation mechanism, which provides linear motion and senses weight-on-bit with a force sensor. There is a passive-contact sensor/stabilizer mechanism that secures the drill fs position on the rock surface, and flex harness management hardware to provide the power and signals to the translating components. The drill housing serves as the primary structure of the turret, to which the additional tools and instruments are attached. The drill bit assembly (DBA) is a passive device that is rotated and hammered in order to cut rock (i.e. science targets) and collect the cuttings (powder) in a sample chamber until ready for transfer to the CHIMRA (Collection and Handling for Interior Martian Rock Analysis). The DBA consists of a 5/8-in. (.1.6- cm) commercial hammer drill bit whose shank has been turned down and machined with deep flutes designed for aggressive cutting removal. Surrounding the shank of the bit is a thick-walled maraging steel collection tube allowing the powdered sample to be augured up the hole into the sample chamber. For robustness, the wall thickness of the DBA was maximized while still ensuring effective sample collection. There are four recesses in the bit tube that are used to retain the fresh bits in their bit box. The rotating bit is supported by a back-to-back duplex bearing pair within a housing that is connected to the outer DBA housing by two titanium diaphragms. The only bearings on the drill in the sample flow are protected by a spring-energized seal, and an integrated shield that diverts the ingested powdered sample from the moving interface. The DBA diaphragms provide radial constraint of the rotating bit and form the sample chambers. Between the diaphragms there is a sample exit tube from which the sample is transferred to the CHIMRA. To ensure that the entire collected sample is retained, no matter the orientation of the drill with respect to gravity during sampling, the pass-through from the forward to the aft chamber resides opposite to the exit tube.

Okon, Avi B.↗

NASA NTRS2013

Hyperspectral Microwave Atmospheric Sounder (HyMAS) Architecture and Design Accommodations

The Hyperspectral Microwave Atmospheric Sounder (HyMAS) is being developed at Lincoln Laboratories and accommodated by the Goddard Space Flight Center for a flight opportunity on a NASA research aircraft. The term "hyperspectral microwave" is used to indicate an all-weather sounding that performs equivalent to hyperspectral infrared sounders in clear air with vertical resolution of approximately 1 km. Deploying the HyMAS equipped scanhead with the existing Conical Scanning Microwave Imaging Radiometer (CoSMIR) shortens the path to a flight demonstration. Hyperspectral microwave is achieved through the use of independent RF antennas that sample the volume of the Earth s atmosphere through various levels of frequencies, thereby producing a set of dense, spaced vertical weighting functions. The simulations proposed for HyMAS 118/183-GHz system should yield surface precipitation rate and water path retrievals for small hail, soft hail, or snow pellets, snow, rainwater, etc. with accuracies comparable to those of the Advanced Technology Microwave Sounder. Further improvements in retrieval methodology (for example, polarization exploitation) are expected. The CoSMIR instrument is a packaging concept re-used on HyMAS to ease the integration features of the scanhead. The HyMAS scanhead will include an ultra-compact Intermediate Frequency Processor (IFP) module that is mounted inside the door to improve thermal management. The IFP is fabricated with materials made of Low-Temperature Co-fired Ceramic (LTCC) technology integrated with detectors, amplifiers, A/D conversion and data aggregation. The IFP will put out 52 channels of 16 bit data comprised of 4-9 channel data streams for temperature profiles and 2-8 channel streams for water vapor. With the limited volume of the existing CoSMIR scanhead and new HyMAS front end components, the HyMAS team at Goddard began preliminary layout work inside the new drum. Importing and re-using models of the shell, the scan head computer, and the slip rings developed for CoSMIR was the starting point. The next step was to modify the antenna faceplate to accommodate the dimensions of the three dual polarization Gaussian Optics Antenna (GOA) assemblies. Two mechanical concepts for the core technology, the hyperspectral IFP, were captured in a design tradeoff. Connector models considered minimum bend radii for the IFP analog connectors. Hyperspectral imaging is accomplished by strategically using a short wavelength intermediate frequency of 18-29 GHz, and thus reducing the size of components in the connection of the front end to the IFP. The SMK (2.92mm) Series connector will lay near the hinge line to minimize its flexing. The digital output of the IFP will use a Serial Peripheral Interface (SPI) that must be accommodated by the scan head computer. To make that computer more reliable, maintainable, and forward compatible with the 52 HyMAS channels, a testbed of the scan head, calibration, and archive computers and the PIC24 microprocessor that resides on the IFP is in development. The computers will be programmed using a new framework application called Interoperable Remote Component (IRC). This software allows flexibility to program computers that communicate with each other and can adapt easily to the emerging HyMAS requirements for data format, algorithms, and graphical user interface (GUI). It is expected that the CoSMIR instrument will cut over to the IRC after it is adapted on an updated CoSMIR testbed.

Hilliard, Lawrence↗

NASA NTRS2013

Pressure-Sensitive Paints Advance Rotorcraft Design Testing

The rotors of certain helicopters can spin at speeds as high as 500 revolutions per minute. As the blades slice through the air, they flex, moving into the wind and back out, experiencing pressure changes on the order of thousands of times a second and even higher. All of this makes acquiring a true understanding of rotorcraft aerodynamics a difficult task. A traditional means of acquiring aerodynamic data is to conduct wind tunnel tests using a vehicle model outfitted with pressure taps and other sensors. These sensors add significant costs to wind tunnel testing while only providing measurements at discrete locations on the model's surface. In addition, standard sensor solutions do not work for pulling data from a rotor in motion. "Typical static pressure instrumentation can't handle that," explains Neal Watkins, electronics engineer in Langley Research Center s Advanced Sensing and Optical Measurement Branch. "There are dynamic pressure taps, but your costs go up by a factor of five to ten if you use those. In addition, recovery of the pressure tap readings is accomplished through slip rings, which allow only a limited amount of sensors and can require significant maintenance throughout a typical rotor test." One alternative to sensor-based wind tunnel testing is pressure sensitive paint (PSP). A coating of a specialized paint containing luminescent material is applied to the model. When exposed to an LED or laser light source, the material glows. The glowing material tends to be reactive to oxygen, explains Watkins, which causes the glow to diminish. The more oxygen that is present (or the more air present, since oxygen exists in a fixed proportion in air), the less the painted surface glows. Imaged with a camera, the areas experiencing greater air pressure show up darker than areas of less pressure. "The paint allows for a global pressure map as opposed to specific points," says Watkins. With PSP, each pixel recorded by the camera becomes an optical pressure tap. "Instead of having 100 or 200 pressure taps, you can have in theory several million, up to whatever the resolution of your camera is." Watkins explains that typical wind tunnel testing requires two models: one with very little instrumentation, and a pressure model with a significant amount of sensors applied. "If you can make all of your measurements on one model with PSP, you've decreased your model costs by at least a factor of two and preferably your testing costs by about that much," he says. PSP technology has been around for almost 20 years, but a PSP solution for gathering instantaneous dynamic pressure data from surfaces moving at high speeds, such as rotor blades, was not available until a NASA partnership led to a game-changing innovation.

Source record↗

NASA NTRS2012

Dynamics of Water Absorption and Evaporation During Methanol Droplet Combustion in Microgravity

The combustion of methanol droplets is profoundly influenced by the absorption and evaporation of water, generated in the gas phase as a part of the combustion products. Initially there is a water-absorption period of combustion during which the latent heat of condensation of water vapor, released into the droplet, enhances its burning rate, whereas later there is a water-evaporation period, during which the water vapor reduces the flame temperature suffciently to extinguish the flame. Recent methanol droplet-combustion experiments in ambient environments diluted with carbon dioxide, conducted in the Combustion Integrated Rack on the International Space Station (ISS), as a part of the FLEX project, provided a method to delineate the water-absorption period from the water-evaporation period using video images of flame intensity. These were obtained using an ultra-violet camera that captures the OH* radical emission at 310 nm wavelength and a color camera that captures visible flame emission. These results are compared with results of ground-based tests in the Zero Gravity Facility at the NASA Glenn Research Center which employed smaller droplets in argon-diluted environments. A simplified theoretical model developed earlier correlates the transition time at which water absorption ends and evaporation starts. The model results are shown to agree reasonably well with experiment.

Hicks, Michael C.↗

NASA NTRS2013

Structural Analysis Using Computer Based Methods

The stiffness of a flex hose that will be used in the umbilical arms of the Space Launch Systems mobile launcher needed to be determined in order to properly qualify ground umbilical plate behavior during vehicle separation post T-0. This data is also necessary to properly size and design the motors used to retract the umbilical arms. Therefore an experiment was created to determine the stiffness of the hose. Before the test apparatus for the experiment could be built, the structure had to be analyzed to ensure it would not fail under given loading conditions. The design model was imported into the analysis software and optimized to decrease runtime while still providing accurate rest~lts and allow for seamless meshing. Areas exceeding the allowable stresses in the structure were located and modified before submitting the design for fabrication. In addition, a mock up of a deep space habitat and the support frame was designed and needed to be analyzed for structural integrity under different loading conditions. The load cases were provided by the customer and were applied to the structure after optimizing the geometry. Once again, weak points in the structure were located and recommended design changes were made to the customer and the process was repeated until the load conditions were met without exceeding the allowable stresses. After the stresses met the required factors of safety the designs were released for fabrication.

Dietz, Matthew R.↗

NASA NTRS2013

Methanol Droplet Combustion in Oxygen-Inert Environments in Microgravity

The Flame Extinguishment (FLEX) experiment that is currently underway in the Combustion Integrated Rack facility onboard the International Space Station is aimed at understanding the effects of inert diluents on the flammability of condensed phase fuels. To this end, droplets of various fuels, including alkanes and alcohols, are burned in a quiescent microgravity environment with varying amounts of oxygen and inert diluents to determine the limiting oxygen index (LOI) for these fuels. In this study we report experimental observations of methanol droplets burning in oxygen-nitrogen-carbon dioxide and oxygen-nitrogen-helium gas mixtures at 0.7 and 1 atmospheric pressures. The initial droplet size varied between approximately 1.5 mm and 4 mm to capture both diffusive extinction brought about by insufficient residence time at the flame and radiative extinction caused by excessive heat loss from the flame zone. The ambient oxygen concentration varied from a high value of 30% by volume to as low as 12%, approaching the limiting oxygen index for the fuel. The inert dilution by carbon dioxide and helium varied over a range of 0% to 70% by volume. In these experiments, both freely floated and tethered droplets were ignited using symmetrically opposed hot-wire igniters and the burning histories were recorded onboard using digital cameras, downlinked later to the ground for analysis. The digital images yielded droplet and flame diameters as functions of time and subsequently droplet burning rate, flame standoff ratio, and initial and extinction droplet diameters. Simplified theoretical models correlate the measured burning rate constant and the flame standoff ratio reasonably well. An activation energy asymptotic theory accounting for time-dependent water dissolution or evaporation from the droplet is shown to predict the measured diffusive extinction conditions well. The experiments also show that the limiting oxygen index for methanol in these diluent gases is around 12% to 13% oxygen by volume.

Nayagam, Vedha↗

NASA NTRS2013

Bulk Metallic Glasses and Composites for Optical and Compliant Mechanisms

Mechanisms are used widely in engineering applications due to their ability to translate force and movement. They are found in kinematic pairs, gears, cams, linkages, and in flexure mechanisms (also known as compliant mechanisms). Mechanisms and flexures are used widely in spacecraft design, especially in the area of optics, where precise positioning of telescope mirrors requires elastic flexing of elements. A compliant mechanism is generally defined as a flexible mechanism that uses an elastic body deformation to cause a displacement (such as positing a mirror). The mechanisms are usually constructed as a single monolithic piece of material, and contain thin struts to allow for large elastic bending with low input force. This creates the largest problem with developing precise mechanisms; they must be fabricated from a single piece of metal, but are required to have strict accuracy on their dimensions. They are generally required to have high strength, elasticity, and low coefficient of thermal expansion.

Hofmann, Douglas C.↗

NASA NTRS2014

Stability Assessment and Tuning of an Adaptively Augmented Classical Controller for Launch Vehicle Flight Control

Recently, a robust and practical adaptive control scheme for launch vehicles [ [1] has been introduced. It augments a classical controller with a real-time loop-gain adaptation, and it is therefore called Adaptive Augmentation Control (AAC). The loop-gain will be increased from the nominal design when the tracking error between the (filtered) output and the (filtered) command trajectory is large; whereas it will be decreased when excitation of flex or sloshing modes are detected. There is a need to determine the range and rate of the loop-gain adaptation in order to retain (exponential) stability, which is critical in vehicle operation, and to develop some theoretically based heuristic tuning methods for the adaptive law gain parameters. The classical launch vehicle flight controller design technics are based on gain-scheduling, whereby the launch vehicle dynamics model is linearized at selected operating points along the nominal tracking command trajectory, and Linear Time-Invariant (LTI) controller design techniques are employed to ensure asymptotic stability of the tracking error dynamics, typically by meeting some prescribed Gain Margin (GM) and Phase Margin (PM) specifications. The controller gains at the design points are then scheduled, tuned and sometimes interpolated to achieve good performance and stability robustness under external disturbances (e.g. winds) and structural perturbations (e.g. vehicle modeling errors). While the GM does give a bound for loop-gain variation without losing stability, it is for constant dispersions of the loop-gain because the GM is based on frequency-domain analysis, which is applicable only for LTI systems. The real-time adaptive loop-gain variation of the AAC effectively renders the closed-loop system a time-varying system, for which it is well-known that the LTI system stability criterion is neither necessary nor sufficient when applying to a Linear Time-Varying (LTV) system in a frozen-time fashion. Therefore, a generalized stability metric for time-varying loop=gain perturbations is needed for the AAC.

VanZwieten, Tannen↗

NASA NTRS2014

Elastic Model Transitions: a Hybrid Approach Utilizing Quadratic Inequality Constrained Least Squares (LSQI) and Direct Shape Mapping (DSM)

A method for transitioning linear time invariant (LTI) models in time varying simulation is proposed that utilizes both quadratically constrained least squares (LSQI) and Direct Shape Mapping (DSM) algorithms to determine physical displacements. This approach is applicable to the simulation of the elastic behavior of launch vehicles and other structures that utilize multiple LTI finite element model (FEM) derived mode sets that are propagated throughout time. The time invariant nature of the elastic data for discrete segments of the launch vehicle trajectory presents a problem of how to properly transition between models while preserving motion across the transition. In addition, energy may vary between flex models when using a truncated mode set. The LSQI-DSM algorithm can accommodate significant changes in energy between FEM models and carries elastic motion across FEM model transitions. Compared with previous approaches, the LSQI-DSM algorithm shows improvements ranging from a significant reduction to a complete removal of transients across FEM model transitions as well as maintaining elastic motion from the prior state.

Jurenko, Robert J.↗

NASA NTRS2014

NASA Wearable Technology CLUSTER 2013-2014 Report

Wearable technology has the potential to revolutionize the way humans interact with one another, with information, and with the electronic systems that surround them. This change can already be seen in the dramatic increase in the availability and use of wearable health and activity monitors. These devices continuously monitor the wearer using on-‐body sensors and wireless communication. They provide feedback that can be used to improve physical health and performance. Smart watches and head mounted displays are also receiving a great deal of commercial attention, providing immediate access to information via graphical displays, as well as additional sensing features. For the purposes of the Wearable Technology CLUSTER, wearable technology is broadly defined as any electronic sensing, human interfaces, computing, or communication that is mounted on the body. Current commercially available wearable devices primarily house electronics in rigid packaging to provide protection from flexing, moisture, and other contaminants. NASA mentors are interested in this approach, but are also interested in direct integration of electronics into clothing to enable more comfortable systems. For human spaceflight, wearable technology holds a great deal of promise for significantly improving safety, efficiency, autonomy, and research capacity for the crew in space and support personnel on the ground. Specific capabilities of interest include: Continuous biomedical monitoring for research and detection of health problems. Environmental monitoring for individual exposure assessments and alarms. Activity monitoring for responsive robotics and environments. Multi-modal caution and warning using tactile, auditory, and visual alarms. Wireless, hands-free, on-demand voice communication. Mobile, on-demand access to space vehicle and robotic displays and controls. Many technical challenges must be overcome to realize these wearable technology applications. For example, to make a wearable device that is both functional and comfortable for long duration wear, developers must strive to reduce electronic mass and volume while also addressing constraints imposed by the body attachment method. Depending on the application, the device must be placed in a location that the user can see and reach, and that provides the appropriate access to air and the wearer's skin. Limited power is available from body-‐worn batteries and heat must be managed to prevent discomfort. If the clothing is to be washed, there are additional durability and washability hurdles that traditional electronics are not designed to address. Finally, each specific capability has unique technical challenges that will likely require unique solutions. In addition to the technical challenges, development of wearable devices is made more difficult by the diversity of skills required and the historic lack of collaboration across domains. Wearable technology development requires expertise in textiles engineering, apparel design, software and computer engineering, electronic design and manufacturing, human factors engineering, and application-‐specific fields such as acoustics, medical devices, and sensing. Knowledge from each of these domains must be integrated to create functional and comfortable devices. For this reason, the diversity of knowledge and experience represented in the Wearable Technology is critical to overcoming the fundamental challenges in the field.

Simon, Cory↗

NASA NTRS2014

Human Performance in Simulated Reduced Gravity Environments

NASA is currently designing a new space suit capable of working in deep space and on Mars. Designing a suit is very difficult and often requires trade‐offs between performance, cost, mass, and system complexity. Our current understanding of human performance in reduced gravity in a planetary environment (the moon or Mars) is limited to lunar observations, studies from the Apollo program, and recent suit tests conducted at JSC using reduced gravity simulators. This study will look at our most recent reduced gravity simulations performed on the new Active Response Gravity Offload System (ARGOS) compared to the C‐9 reduced gravity plane. Methods: Subjects ambulated in reduced gravity analogs to obtain a baseline for human performance. Subjects were tested in lunar gravity (1.6 m/sq s) and Earth gravity (9.8 m/sq s) in shirt‐sleeves. Subjects ambulated over ground at prescribed speeds on the ARGOS, but ambulated at a self‐selected speed on the C‐9 due to time limitations. Subjects on the ARGOS were given over 3 minutes to acclimate to the different conditions before data was collected. Nine healthy subjects were tested in the ARGOS (6 males, 3 females, 79.5 +/- 15.7 kg), while six subjects were tested on the C‐9 (6 males, 78.8 +/- 11.2 kg). Data was collected with an optical motion capture system (Vicon, Oxford, UK) and was analyzed using customized analysis scripts in BodyBuilder (Vicon, Oxford, UK) and MATLAB (MathWorks, Natick, MA, USA). Results: In all offloaded conditions, variation between subjects increased compared to 1‐g. Kinematics in the ARGOS at lunar gravity resembled earth gravity ambulation more closely than the C‐9 ambulation. Toe‐off occurred 10% earlier in both reduced gravity environments compared to earth gravity, shortening the stance phase. Likewise, ankle, knee, and hip angles remained consistently flexed and had reduced peaks compared to earth gravity. Ground reaction forces in lunar gravity (normalized to Earth body weight) were 0.4 +/- 0.2 on the ARGOS, but only 0.2 +/- 0.1 on the C‐9. Discussion: Gait analysis showed differences in joint kinematics and temporal‐spatial parameters between the reduced gravity simulators and with respect to earth gravity. Although most of the subjects chose a somewhat unique ambulation style as a result of learning to ambulate in a new environment, all but two were consistent with keeping an Earth‐like gait. Learning how reduced gravity affects ambulation will help NASA to determine optimal suit designs, influence mission planning, help train crew, and may shed light on the underlying methods the body uses to optimize gait for energetic efficiency. Conclusion: Kinematic and kinetic analysis demonstrated noteworthy differences between an offloaded environment and 1‐g, as would be expected. The analysis showed a trend to change the ambulation style in an offloaded environment to a rolling‐loping walk (resembling crosscountry skiing) with increased swing time. This ambulation modification, particularly in the ARGOS, indicated that the relative kinetic energy of the subject was increased, on average, per the static body weight compared to the 1‐g condition. How much of this was influenced by the active offloading of the ARGOS system is unknown.

Cowley, Matthew↗

NASA NTRS2014

Dust Tolerant Commodity Transfer Interface Mechanisms for Planetary Surfaces

Regolith is present on most planetary surfaces such as Earth's moon, Mars, and Asteroids. If human crews and robotic machinery are to operate on these regolith covered surfaces, they must face the consequences of interacting with regolith fines which consist of particles below 100 microns in diameter down to as small as submicron scale particles. Such fine dust will intrude into mechanisms and interfaces causing a variety of problems such as contamination of clean fluid lines, jamming of mechanisms and damaging connector seals and couplings. Since multiple elements must be assembled in space for system level functionality, it will be inevitable that interfaces will be necessary for structural connections, and to pass commodities such as cryogenic liquid propellants, purge and buffer gases, water, breathing air, pressurizing gases, heat exchange fluids, power and data. When fine regolith dust is present in the environment it can be lofted into interfaces where it can compromise the utility of the interface by preventing the connections from being successfully mated, or by inducing fluid leaks or degradation of power and data transmission. A dust tolerant, hand held "quick-disconnect" cryogenic fluids connector housing has been developed at NASA KSC which can be used by astronaut crews to connect flex lines that will transfer propellants and other useful fluids to the end user. In addition, a dust tolerant, automated, cryogenic fluid, multiple connector, power and data interface mechanism prototype has been developed, fabricated and demonstrated by NASA at Kennedy Space Center (KSC). The design and operation of these prototypes are explained and discussed.

Dust Tolerant↗

NASA NTRS2014

Deployment Methods for an Origami-Inspired Rigid-Foldable Array

The purpose of this work is to evaluate several deployment methods for an origami-inspired solar array at two size scales: 25-meter array and CubeSat array. The array enables rigid panel deployment and introduces new concepts for actuating CubeSat deployables. The design for the array was inspired by the origami flasher model (Lang, 1997; Shafer, 2001). Figure 1 shows the array prototyped from Garolite and Kapton film at the CubeSat scale. Prior work demonstrated that rigid panels like solar cells could successfully be folded into the final stowed configuration without requiring the panels to flex (Zirbel, Lang, Thomson, & al., 2013). The design of the array is novel and enables efficient use of space. The array can be wrapped around the central bus of the spacecraft in the case of the large array, or can accommodate storage of a small instrument payload in the case of the CubeSat array. The radial symmetry of this array around the spacecraft is ideally suited for spacecraft that need to spin. This work focuses on several actuation methods for a one-time deployment of the array. The array is launched in its stowed configuration and it will be deployed when it is in space. Concepts for both passive and active actuation were considered.

Zirbel, Shannon A.↗

NASA NTRS2015

Advanced Launch Technology Life Cycle Analysis Using the Architectural Comparison Tool (ACT)

Life cycle technology impact comparisons for nanolauncher technology concepts were performed using an Affordability Comparison Tool (ACT) prototype. Examined are cost drivers and whether technology investments can dramatically affect the life cycle characteristics. Primary among the selected applications was the prospect of improving nanolauncher systems. As a result, findings and conclusions are documented for ways of creating more productive and affordable nanolauncher systems; e.g., an Express Lane-Flex Lane concept is forwarded, and the beneficial effect of incorporating advanced integrated avionics is explored. Also, a Functional Systems Breakdown Structure (F-SBS) was developed to derive consistent definitions of the flight and ground systems for both system performance and life cycle analysis. Further, a comprehensive catalog of ground segment functions was created.

Space Flight Architecture↗

NASA NTRS2014

Fully Integral, Flexible Composite Driveshaft

An all-composite driveshaft incorporating integral flexible diaphragms was developed for prime contractor testing. This new approach makes obsolete the split lines required to attach metallic flex elements and either metallic or composite spacing tubes in current solutions. Subcritical driveshaft weights can be achieved that are half that of incumbent technology for typical rotary wing shaft lengths. Spacing tubes compose an integral part of the initial tooling but remain part of the finished shaft and control natural frequencies and torsional stability. A concurrently engineered manufacturing process and design for performance competes with incumbent solutions at significantly lower weight and with the probability of improved damage tolerance and fatigue life.

Lawrie, Duncan↗

NASA NTRS2015

Monitoring Human Performance During Suited Operations: A Technology Feasibility Study Using EMU Gloves

Mobility tracking of human subjects while conducting suited operations still remains focused on the external movement of the suit and little is known about the human movement within it. For this study, accelerometers and bend sensitive resistors were integrated into a custom carrier glove to quantify range of motion and dexterity from within the pressurized glove environment as a first stage feasibility study of sensor hardware, integration, and reporting capabilities. Sensors were also placed on the exterior of the pressurized glove to determine if it was possible to compare a glove joint angle to the anatomical joint angle of the subject during tasks. Quantifying human movement within the suit was feasible, with accelerometers clearly detecting movements in the wrist and reporting expected joint angles at maximum flexion or extension postures with repeatability of plus or minus 5 degrees between trials. Bend sensors placed on the proximal interphalangeal and distal interphalangeal joints performed less well. It was not possible to accurately determine the actual joint angle using these bend sensors, but these sensors could be used to determine when the joint was flexed to its maximum and provide a general range of mobility needed to complete a task. Further work includes additional testing with accelerometers and the possible inclusion of hardware such as magnetometers or gyroscopes to more precisely locate the joint in 3D space. We hope to eventually expand beyond the hand and glove and develop a more comprehensive suit sensor suite to characterize motion across more joints (knee, elbow, shoulder, etc.) and fully monitor the human body operating within the suit environment.

Bekdash, Omar↗