SEARCH · Engineering Papers
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.
This powerpoint presentation describes the occupant protection project for the Orion Crew Vehicle. Background information on the Orion Crew Vehicle along with comparisons of the Space Shuttle, Ares I, Ares V, Saturn V and Soyuz-FG are also described. The contents include: 1) Background and Overview; 2) Crew health and safety overview; 3) Occupant Protection project overview; and 4) Suit Element injury risk.
Air bags were evaluated as the landing attenuation system for earth landing of the Orion Crew Module (CM). Analysis conducted to date shows that airbags are capable of providing a graceful landing of the CM in nominal and off-nominal conditions such as parachute failure, high horizontal winds, and unfavorable vehicle/ground angle combinations, while meeting crew and vehicle safety requirements. The analyses and associated testing presented here surround a second generation of the airbag design developed by ILC Dover, building off of relevant first-generation design, analysis, and testing efforts. In order to fully evaluate the second generation air bag design and correlate the dynamic simulations, a series of drop tests were carried out at NASA Langley s Landing and Impact Research (LandIR) facility in Hampton, Virginia. The tests consisted of a full-scale set of air bags attached to a full-scale test article representing the Orion Crew Module. The techniques used to collect experimental data, develop the simulations, and make comparisons to experimental data are discussed.
Systems engineering could also be called the art of compromise. At its heart, systems engineering seeks to find that solution which maximizes the utility of the system, usually compromising the performance of each individual subsystem. While seemingly straightforward, systems engineering methodology is complicated when the utility to be maximized is unclear and the costs to each individual subsystem are not - or not easily - quantifiable. In this paper, we explore one such systems engineering problem within the Constellation Program as a case study in applied systems engineering. During suited operations, astronauts within Orion will be connected to an umbilical to receive and return breathing gas. The pressure drop associated with this umbilical must be overcome by the Orion vehicle. A smaller umbilical, which is desirable for crew operations, means a higher pressure drop, resulting in additional mass and power for the vehicle. We outline the technical considerations in the development of this integrated system and discuss the method by which we reached the ultimate solution. This paper, while just one example of the kind of problem solving that happens every day, offers insight into what happens when the theories of systems engineering are put into practice.
NASA's Orion Crew Exploration Vehicle (CEV) will provide transportation for crew and cargo to and from destinations in support of the Constellation Architecture Design Reference Missions. Discrete Event Simulation (DES) is one of the design methods NASA employs for crew performance of the CEV. During the early development of the CEV, NASA and its prime Orion contractor Lockheed Martin (LM) strived to seek an effective low-cost method for developing and validating human performance DES models. This paper focuses on the method developed while creating a DES model for the CEV Rendezvous, Proximity Operations, and Docking (RPOD) task to the International Space Station. Our approach to validation was to attack the problem from several fronts. First, we began the development of the model early in the CEV design stage. Second, we adhered strictly to M&S development standards. Third, we involved the stakeholders, NASA astronauts, subject matter experts, and NASA's modeling and simulation development community throughout. Fourth, we applied standard and easy-to-conduct methods to ensure the model's accuracy. Lastly, we reviewed the data from an earlier human-in-the-loop RPOD simulation that had different objectives, which provided us an additional means to estimate the model's confidence level. The results revealed that a majority of the DES model was a reasonable representation of the current CEV design.
The Orion vehicle will be designed to perform several rendezvous missions: rendezvous with the ISS in Low Earth Orbit (LEO), rendezvous with the EDS/Altair in LEO, a contingency rendezvous with the ascent stage of the Altair in Low Lunar Orbit (LLO) and a contingency rendezvous in LLO with the ascent and descent stage in the case of an aborted lunar landing. Therefore, it is not difficult to realize that each of these scenarios imposes different operational, timing, and performance constraints on the GNC system. To this end, a suite of on-board guidance and targeting algorithms have been designed to meet the requirement to perform the rendezvous independent of communications with the ground. This capability is particularly relevant for the lunar missions, some of which may occur on the far side of the moon. This paper will describe these algorithms which are designed to be structured and arranged in such a way so as to be flexible and able to safely perform a wide variety of rendezvous trajectories. The goal of the algorithms is not to merely fly one specific type of canned rendezvous profile. Conversely, it was designed from the start to be general enough such that any type of trajectory profile can be flown.(i.e. a coelliptic profile, a stable orbit rendezvous profile, and a expedited LLO rendezvous profile, etc) all using the same rendezvous suite of algorithms. Each of these profiles makes use of maneuver types which have been designed with dual goals of robustness and performance. They are designed to converge quickly under dispersed conditions and they are designed to perform many of the functions performed on the ground today. The targeting algorithms consist of a phasing maneuver (NC), an altitude adjust maneuver (NH), and plane change maneuver (NPC), a coelliptic maneuver (NSR), a Lambert targeted maneuver, and several multiple-burn targeted maneuvers which combine one of more of these algorithms. The derivation and implementation of each of these algorithms will be discussed in detail, as well and the Rendezvous Targeting "wrapper" which will sequentially tie them all together into a single onboard targeting tool which can produce a final integrated rendezvous trajectory. In a similar fashion, the various guidance modes available for flying out each of these maneuvers will be discussed as well. This paradigm of having the onboard guidance & targeting capability described above is different than the way the Space Shuttle has operated thus far. As a result, a discussion of these differences in terms of operations and ground and crew intervention will also be discussed. However, the general framework of how the mission designers on the ground first perform all mission design and planning functions, and then uplink that burn plan to the vehicle ensures that the ground will be involved to ensure safety and reliability. The only real difference is which of these functions will be done onboard vs. on the ground as done currently. Finally, this paper will describe the performance of each of these algorithms individually as well as the entire suite of algorithms as applied to the Orion ISS and EDS/Altair rendezvous missions in LEO. These algorithms have been incorporated in both a Linear Covariance environment and a Monte Carlo environment and the results of these dispersion analyses will be presented in the paper as well.
The first flight test of the Orion Abort Flight Test project is scheduled to launch in Spring 2010. This flight test is known as Pad Abort 1 (PA-1) and it is intended to accomplish a series of flight test objectives, including demonstrating the capability of the Launch Abort System (LAS) to propel the Crew Module (CM) to a safe distance from a launch vehicle during a pad abort. The PA-1 Flight Test Article (FTA) is actively controlled by a guidance, navigation, and control (GN&C) system for much of its flight. The purpose of this paper is to describe the design, development, and analysis of the PA-1 GN&C system. A description of the technical solutions that were developed to meet the challenge of satisfying many competing requirements is presented. A historical perspective of how the Orion LAV compares to the Apollo Launch Escape Vehicle (LEV) design will also be included.
Plume impingement effects on the Orion Crew Service Module (CSM) were analyzed for various dual Reaction Control System (RCS) engine firings and various configurations of the solar arrays. The study was performed using a decoupled computational fluid dynamics (CFD) and Direct Simulation Monte Carlo (DSMC) approach. This approach included a single jet plume solution for the R1E RCS engine computed with the General Aerodynamic Simulation Program (GASP) CFD code. The CFD solution was used to create an inflow surface for the DSMC solution based on the Bird continuum breakdown parameter. The DSMC solution was then used to model the dual RCS plume impingement effects on the entire CSM geometry with deployed solar arrays. However, because the continuum breakdown parameter of 0.5 could not be achieved due to geometrical constraints and because high resolution in the plume shock interaction region is desired, a focused DSMC simulation modeling only the plumes and the shock interaction region was performed. This high resolution intermediate solution was then used as the inflow to the larger DSMC solution to obtain plume impingement heating, forces, and moments on the CSM and the solar arrays for a total of 21 cases that were analyzed. The results of these simulations were used to populate the Orion CSM Aerothermal Database.
At touchdown Orion must be aligned so that the crew person's feet are forward in the direction of the horizontal velocity. To ensure that this requirement is met active heading control is being implemented on the Orion crew module. This technique reduces probability of roll-over during splashdown, assures axial loads on the crew at touchdown, and alleviates structural requirements on impact allowing for a light-weight structural design. On-board sensors are used to measure current vehicle orientation and horizontal velocity used in generation of the heading error signal. Linear velocity measured by the IMU drifts while under parachutes due to wind gusts and has to be corrected by GPS; this makes GPS critical for successful landing. Jet fire logic is achieved by use of a phase-plane and commands are realized by using roll jets from the reaction control system (RCS); using pre existing hardware eliminates additional hardware and structural requirements. Touchdown performance is measured by an orientation envelope that was co-developed with structures so that the performance requirements overlap adding system redundancy. Heading control also introduces new difficulties to be addressed such as parachute line twist torque as well as increasing vehicle sensitivity to wind shifts and sea states. Solving these difficulties requires added complexity to flight software as well as increasing the propellant required to achieve successful touchdown. while offering promising results, the criticality of GPS along with a significant propellant cost raises questions on the effectiveness of using touchdown heading control.
The present ground based investigations give the first definitive look describing the charging behavior of Orion UltraFlex arrays in both the Low Earth Orbital (LEO) and geosynchronous (GEO) environments. Note the LEO charging environment also applies to the International Space Station (ISS). The GEO charging environment includes the bounding case for all lunar mission environments. The UltraFlex photovoltaic array technology is targeted to become the sole power system for life support and on-orbit power for the manned Orion Crew Exploration Vehicle (CEV). The purpose of the experimental tests is to gain an understanding of the complex charging behavior to answer some of the basic performance and survivability issues to ascertain if a single UltraFlex array design will be able to cope with the projected worst case LEO and GEO charging environments. Stage 1 LEO plasma testing revealed that all four arrays successfully passed arc threshold bias tests down to -240 V. Stage 2 GEO electron gun charging tests revealed that only the front side area of indium tin oxide coated array designs successfully passed the arc frequency tests
The Orion On-board GNC system is among the most complex ever developed for a space mission. It is designed to operate autonomously (independent of the ground). The rendezvous system in particular was designed to operate on the far side of the moon, and in the case of loss-of-communications with the ground. The vehicle GNC system is designed to retarget the rendezvous maneuvers, given a mission plan. As such, all the maneuvers which will be performed by Orion, have been designed and are being incorporated into the flight code.
A study was performed to determine if a Design of Experiments (DOE)/Response Surface Methodology could be applied to on-orbit thermal analysis and produce a set of Response Surface Equations (RSE) that accurately predict vehicle temperatures. The study used an integrated thermal model of the International Space Station and the Orion Outer mold line model. Five separate factors were identified for study: yaw, pitch, roll, beta angle, and the environmental parameters. Twenty external Orion temperatures were selected as the responses. A DOE case matrix of 110 runs was developed. The data from these cases were analyzed to produce an RSE for each of the temperature responses. The initial agreement between the engineering data and the RSE predictions was encouraging, although many RSEs had large uncertainties on their predictions. Fourteen verification cases were developed to test the predictive powers of the RSEs. The verification showed mixed results with some RSE predicting temperatures matching the engineering data within the uncertainty bands, while others had very large errors. While this study to not irrefutably prove that the DOE/RSM approach can be applied to on-orbit thermal analysis, it does demonstrate that technique has the potential to predict temperatures. Additional work is needed to better identify the cases needed to produce the RSEs
This slide presentation reviews NASA's work in development of landing and recovery systems for the Orion space craft. It includes a review of the available tools and skills that assist in analyzing the aerodynamic decelerators. There is a description of the work that is being done on the Government Furnished Equipment (GFE) parachutes that will be used with the Orion Crew Exploration Vehicle (CEV)
This paper presents the tests and analytical approach used on the development of a steel riser cutter for the CEV Parachute Assembly System (CPAS) used on the Orion crew module. Figure 1 shows the riser cutter and the steel riser bundle which consists of six individual cables. Due to the highly compressed schedule, initial unavailability of the riser material and the Orion Forward Bay mechanical constraints, JSC primarily relied on a combination of internal ballistics analysis and LS-DYNA simulation for this project. Various one dimensional internal ballistics codes that use standard equation of state and conservation of energy have commonly used in the development of CAD devices for initial first order estimates and as an enhancement to the test program. While these codes are very accurate for propellant performance prediction, they usually lack a fully defined kinematic model for dynamic predictions. A simple piston device can easily and accurately be modeled using an equation of motion. However, the accuracy of analytical models is greatly reduced on more complicated devices with complex external loads, nonlinear trajectories or unique unlocking features. A 3D finite element model of CAD device with all critical features included can vastly improve the analytical ballistic predictions when it is used as a supplement to the ballistic code. During this project, LS-DYNA structural 3D model was used to predict the riser resisting load that was needed for the ballistic code. A Lagrangian model with eroding elements shown in Figure 2 was used for the blade, steel riser and the anvil. The riser material failure strain was fine tuned by matching the dent depth on the anvil with the actual test data. LS-DYNA model was also utilized to optimize the blade tip design for the most efficient cut. In parallel, the propellant type and the amount were determined by using CADPROG internal ballistics code. Initial test results showed a good match with LS-DYNA and CADPROG simulations. Final paper will present a detailed roadmap from initial ballistic modeling and LS-DYNA simulation to the performance testing. Blade shape optimization study will also be presented.
The active thermal control system (ATCS) of the crew exploration vehicle (Orion) uses radiator panels with fluid loops as the primary system to reject heat from spacecraft. The Lockheed Martin (LM) baseline Orion ATCS uses eight-panel radiator coated with silver Teflon coating (STC) for International Space Station (ISS) missions, and uses seven-panel radiator coated with AZ 93 white paint for lunar missions. As an option to increase the radiator area with minimal impact on other component locations and interfaces, the reduced-curvature (RC) radiator concept was introduced and investigated here for the thermal perspective. Each RC radiator panel has 15 percent more area than each Lockheed Martin (LM) baseline radiator panel. The objective was to determine if the RC seven-panel radiator concept could be used in the ATCS for both ISS and lunar missions. Three radiator configurations the LM baseline, an RC seven-panel radiator with STC, and an RC seven-panel radiator with AZ 93 coating were considered in the ATCS for ISS missions. Two radiator configurations the LM baseline and an RC seven-panel radiator with AZ 93 coating were considered in the ATCS for lunar missions. A Simulink/MATLAB model of the ATCS was used to compute the ATCS performance. Some major hot phases on the thermal timeline were selected because of concern about the large amount of water sublimated for thermal topping. It was concluded that an ATCS with an RC seven-panel radiator could be used for both ISS and lunar missions, but with two different coatings STC for ISS missions and AZ 93 for lunar missions to provide performance similar to or better than that of the LM baseline ATCS.
The Constellation Program (CxP) Orion vehicle goes through several areas and stages of processing before its launched at the Kennedy Space Center. In order to have efficient and effective processing, all of the activities need to be analyzed. This was accomplished by first developing a timeline of events that included each activity, and then each activity was analyzed by operability experts and human factors experts with spacecraft processing experience. This papers focus is to explain the results and the process for developing this human factors operability timeline analysis to improve the processing flow of Orion.
The Orion Command Module (CM) is a capsule designed to bring crew back from the International Space Station (ISS), the moon and beyond. The atmospheric entry portion of the flight is deigned to be flown in autopilot mode for nominal situations. However, there exists the possibility for the crew to take over manual control in off-nominal situations. In these instances, the spacecraft must meet specific handling qualities criteria. To address these criteria two separate assessments of the Orion CM s entry Handling Qualities (HQ) were conducted at NASA s Johnson Space Center (JSC) using the Cooper-Harper scale (Cooper & Harper, 1969). These assessments were conducted in the summers of 2008 and 2010 using the Advanced NASA Technology Architecture for Exploration Studies (ANTARES) six degree of freedom, high fidelity Guidance, Navigation, and Control (GN&C) simulation. This paper will address the specifics of the handling qualities criteria, the vehicle configuration, the scenarios flown, the simulation background and setup, crew interfaces and displays, piloting techniques, ratings and crew comments, pre- and post-fight briefings, lessons learned and changes made to improve the overall system performance. The data collection tools, methods, data reduction and output reports will also be discussed. The objective of the 2008 entry HQ assessment was to evaluate the handling qualities of the CM during a lunar skip return. A lunar skip entry case was selected because it was considered the most demanding of all bank control scenarios. Even though skip entry is not planned to be flown manually, it was hypothesized that if a pilot could fly the harder skip entry case, then they could also fly a simpler loads managed or ballistic (constant bank rate command) entry scenario. In addition, with the evaluation set-up of multiple tasks within the entry case, handling qualities ratings collected in the evaluation could be used to assess other scenarios such as the constant bank angle maintenance case. The 2008 entry assessment was divided into two sections (see Figure 1). Entry I was the first, high speed portion of a lunar return and Entry II was the second, lower speed portion of a lunar return, which is similar (but not identical) to a typical ISS return.
Computational Fluid Dynamics (CFD) is used to model the flow field in the Orion CEV cabin. The CFD model employs a momentum model used to account for the effect of supply grilles on the supply flow. The momentum model is modified to account for non-uniform velocity profiles at the approach of the supply grille. The modified momentum model is validated against a detailed vane-resolved model before inclusion into the Orion CEV cabin model. Results for this comparison, as well as that of a single ventilation configuration are presented.
Two piloted simulations were conducted at NASA's Johnson Space Center using the Cooper-Harper scale to study the handling qualities of the Orion Command Module capsule during atmospheric entry flight. The simulations were conducted using high fidelity 6-DOF simulators for Lunar Return Skip Entry and International Space Station Return Direct Entry flight using bank angle steering commands generated by either the Primary (PredGuid) or Backup (PLM) guidance algorithms. For both evaluations, manual control of bank angle began after descending through Entry Interface into the atmosphere until drogue chutes deployment. Pilots were able to use defined bank management and reversal criteria to accurately track the bank angle commands, and stay within flight performance metrics of landing accuracy, g-loads, and propellant consumption, suggesting that the pilotability of Orion under manual control is both achievable and provides adequate trajectory performance with acceptable levels of pilot effort. Another significant result of these analyses is the applicability of flying a complex entry task under high speed entry flight conditions relevant to the next generation Multi Purpose Crew Vehicle return from Mars and Near Earth Objects.