Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “gimbals”

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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Self-Referencing Hartmann Test for Large-Aperture Telescopes

A method is proposed for end-to-end, full aperture testing of large-aperture telescopes using an innovative variation of a Hartmann mask. This technique is practical for telescopes with primary mirrors tens of meters in diameter and of any design. Furthermore, it is applicable to the entire optical band (near IR, visible, ultraviolet), relatively insensitive to environmental perturbations, and is suitable for ambient laboratory as well as thermal-vacuum environments. The only restriction is that the telescope optical axis must be parallel to the local gravity vector during testing. The standard Hartmann test utilizes an array of pencil beams that are cut out of a well-corrected wavefront using a mask. The pencil beam array is expanded to fill the full aperture of the telescope. The detector plane of the telescope is translated back and forth along the optical axis in the vicinity of the nominal focal plane, and the centroid of each pencil beam image is recorded. Standard analytical techniques are then used to reconstruct the telescope wavefront from the centroid data. The expansion of the array of pencil beams is usually accomplished by double passing the beams through the telescope under test. However, this requires a well-corrected, autocollimation flat, the diameter or which is approximately equal to that of the telescope aperture. Thus, the standard Hartmann method does not scale well because of the difficulty and expense of building and mounting a well-corrected, large aperture flat. The innovation in the testing method proposed here is to replace the large aperture, well-corrected, monolithic autocollimation flat with an array of small-aperture mirrors. In addition to eliminating the need for a large optic, the surface figure requirement for the small mirrors is relaxed compared to that required of the large autocollimation flat. The key point that allows this method to work is that the small mirrors need to operate as a monolithic flat only with regard to tip/tilt and not piston because in collimated space piston has no effect on the image centroids. The problem of aligning the small mirrors in tip/tilt requires a two-part solution. First, each mirror is suspended from a two-axis gimbal. The orientation of the gimbal is maintained by gravity. Second, the mirror is aligned such that the mirror normal is parallel to gravity vector. This is accomplished interferometrically in a test fixture. Of course, the test fixture itself needs to be calibrated with respect to gravity.

Korechoff, Robert P.↗
NASA NTRS2010

A Two-Axis Direct Fluid Shear Stress Sensor

This innovation is a miniature or micro sized semiconductor sensor design that provides two axis direct non-intrusive measurement of skin friction or wall shear stress in fluid flow. The sensor is fabricated by micro-electro-mechanical system (MEMS) technology, enabling small size and low cost reproductions. The sensors have been fabricated by utilizing MEMS fabrication processes to bond a sensing element wafer to a fluid coupling wafer. This layering technique provides for an out of plane dimension that is on the same order of length as the inplane dimensions. The sensor design has the following characteristics: a shear force collecting plate with dimensions that can be tailored to various application specific requirements such as spatial resolution, temporal resolution and shear force range and resolution. This plate is located coplanar to both the sensor body and flow boundary, and is connected to a dual axis gimbal structure by a connecting column or lever arm. The dual axis gimbal structure has torsional hinges with embedded piezoresistive torsional strain gauges which provide a voltage output that is correlated to the applied shear stress (and excitation current) on force collection plate that is located on the flow boundary surface (hence the transduction method). This combination of design elements create a force concentration and resolution structure that enables the generation of a large stress on the strain gauge from the small shear stress on the flow boundary wall. This design as well as the use of back side electrical contacts establishes a non-intrusive method to quantitatively measure the shear force vector on aerodynamic bodies.

Adcock, Edward E.↗
NASA NTRS2010

A New Method for Interfacing Unsuited Subjects to Overhead Suspension Partial Gravity Simulators

The purpose of performing unsuited testing as part of a reduced gravity extravehicular (EVA) suited human performance research program is to define baseline performance. These results are then coupled with suited test results to evaluate how the suit system affects human performance at reduced gravity. The primary drawback to this approach is that previous studies used notably different systems to interface suited and unsuited subjects to overhead-suspension, partial-gravity simulators. A spreader bar (SB) assembly previously used for unsuited tests allowed limited pitch and roll of the subject, whereas the gimbal for suited tests allowed more pitch and roll, although the mass distribution led to large moments of inertia in the yaw axis. It is hypothesized that use of the same methods for offload of both unsuited and suited subjects is needed to make meaningful comparisons. A new gimbal (GIM) was designed with the idea that it could function with both suited and unsuited subjects. GIM was designed to minimize mass and moments of inertia and to be adjustable to co-locate the 3 axes of rotation with the subject s center of gravity. OBJECTIVE: To evaluate human performance differences between SB and GIM. METHODS: Ten unsuited subjects were off-loaded to 1/6-g using both interfaces. Subjects completed tasks including overground and treadmill ambulation, picking up objects, shoveling, postural stability, range of motion testing, and recovery from the kneeling and prone positions. Metabolic, biomechanical, and/or subjective data were collected based on task. RESULTS: Initial analyses suggest that subjects completed all tasks with lower levels of compensation and a more terrestrial approach to movement when suspended via GIM. With SB, subjects were not able to fall or get into a prone position and had increased difficulty both retrieving objects off the floor and with overground ambulation, especially at gait initiation, because they were unable to bend their torso. GIM shows promise as a new method.

Norcross, Jason R.↗
NASA NTRS2011

A New Method for Interfacing Unsuited Subjects to Overhead Suspension Partial Gravity Simulators

The purpose of performing unsuited testing as part of a reduced gravity extravehicular (EVA) suited human performance research program is to define baseline performance. These results are then coupled with suited test results to evaluate how the suit system affects human performance at reduced gravity. The primary drawback to this approach is that previous studies used notably different systems to interface suited and unsuited subjects to overhead-suspension, partial-gravity simulators. A spreader bar (SB) assembly previously used for unsuited tests allowed limited pitch and roll of the subject, whereas the gimbal for suited tests allowed more pitch and roll, although the mass distribution led to large moments of inertia in the yaw axis. It is hypothesized that use of the same methods for offload of both unsuited and suited subjects is needed to make meaningful comparisons. A new gimbal (GIM) was designed with the idea that it could function with both suited and unsuited subjects. GIM was designed to minimize mass and moments of inertia and to be adjustable to co-locate the 3 axes of rotation with the subject s center of gravity. OBJECTIVE: To evaluate human performance differences between SB and GIM. METHODS: Ten unsuited subjects were offloaded to 1/6-g using both interfaces. Subjects completed tasks including overground and treadmill ambulation, picking up objects, shoveling, postural stability, range of motion testing, and recovery from the kneeling and prone positions. Metabolic, biomechanical, and/or subjective data were collected based on task. RESULTS: Initial analyses suggest that subjects completed all tasks with lower levels of compensation and a more terrestrial approach to movement when suspended via GIM. With SB, subjects were not able to fall or get into a prone position and had increased difficulty both retrieving objects off the floor and with overground ambulation, especially at gait initiation, because they were unable to bend their torso. GIM shows promise as a new method.

Norcross, Jason↗
NASA NTRS2013

Simple Laser Communications Terminal for Downlink from Earth Orbit at Rates Exceeding 10 Gb/s

A compact, low-cost laser communications transceiver was prototyped for downlinking data at 10 Gb/s from Earth-orbiting spacecraft. The design can be implemented using flight-grade parts. With emphasis on simplicity, compactness, and light weight of the flight transceiver, the reduced-complexity design and development approach involves: 1. A high-bandwidth coarse wavelength division multiplexed (CWDM) (4 2.5 or 10-Gb/s data-rate) downlink transmitter. To simplify the system, emphasis is on the downlink. Optical uplink data rate is modest (due to existing and adequate RF uplink capability). 2. Highly simplified and compact 5-cm diameter clear aperture optics assembly is configured to single transmit and receive aperture laser signals. About 2 W of 4-channel multiplexed (1,540 to 1,555 nm) optically amplified laser power is coupled to the optical assembly through a fiber optic cable. It contains a highly compact, precision-pointing capability two-axis gimbal assembly to coarse point the optics assembly. A fast steering mirror, built into the optical path of the optical assembly, is used to remove residual pointing disturbances from the gimbal. Acquisition, pointing, and tracking are assisted by a beacon laser transmitted from the ground and received by the optical assembly, which will allow transmission of a laser beam. 3. Shifting the link burden to the ground by relying on direct detection optical receivers retrofitted to 1-m-diameter ground telescopes. 4. Favored mass and volume reduction over power-consumption reduction. The two major variables that are available include laser transmit power at either end of the link, and telescope aperture diameter at each end of the link. Increased laser power is traded for smaller-aperture diameters. 5. Use of commercially available spacequalified or qualifiable components with traceability to flight qualification (i.e., a flight-qualified version is commercially available). An example is use of Telecordia-qualified fiber optic communication components including active components (lasers, amplifiers, photodetectors) that, except for vacuum and radiation, meet most of the qualifications required for space. 6. Use of CWDM technique at the flight transmitter for operation at four channels (each at 2.5 Gb/s or a total of 10 Gb/s data rate). Applying this technique allows utilization of larger active area photodetectors at the ground station. This minimizes atmospheric scintillation/turbulence induced losses on the received beam at the ground terminal. 7. Use of forward-error-correction and deep-interleaver codes to minimize atmospheric turbulence effects on the downlink beam. Target mass and power consumption for the flight data transmitter system is less than 10 kg and approximately 60 W for the 400-km orbit (900-km slant range), and 12 kg and 120 W for the 2,000-km orbit (6,000-km slant range). The higher mass and power for the latter are the result of employing a higher-power laser only.

Kovalik, Joseph M.↗
NASA NTRS2011

Hardware Testing for the Optical PAyload for Lasercomm Science (OPALS)

Hardware for several subsystems of the proposed Optical PAyload for Lasercomm Science (OPALS), including the gimbal and avionics, was tested. Microswitches installed on the gimbal were evaluated to verify that their point of actuation would remain within the acceptable range even if the switches themselves move slightly during launch. An inspection of the power board was conducted to ensure that all power and ground signals were isolated, that polarized components were correctly oriented, and that all components were intact and securely soldered. Initial testing on the power board revealed several minor problems, but once they were fixed the power board was shown to function correctly. All tests and inspections were documented for future use in verifying launch requirements.

optical communications↗
NASA NTRS2010

Preliminary Design of the Guidance, Navigation, and Control System of the Altair Lunar Lander

Guidance, Navigation, and Control (GN&C) is the measurement and control of spacecraft position, velocity, and attitude in support of mission objectives. This paper provides an overview of a preliminary design of the GN&C system of the Lunar Lander Altair. Key functions performed by the GN&C system in various mission phases will first be described. A set of placeholder GN&C sensors that is needed to support these functions is next described. To meet Crew safety requirements, there must be high degrees of redundancy in the selected sensor configuration. Two sets of thrusters, one on the Ascent Module (AM) and the other on the Descent Module (DM), will be used by the GN&C system. The DM thrusters will be used, among other purposes, to perform course correction burns during the Trans-lunar Coast. The AM thrusters will be used, among other purposes, to perform precise angular and translational controls of the ascent module in order to dock the ascent module with Orion. Navigation is the process of measurement and control of the spacecraft's "state" (both the position and velocity vectors of the spacecraft). Tracking data from the Earth-Based Ground System (tracking antennas) as well as data from onboard optical sensors will be used to estimate the vehicle state. A driving navigation requirement is to land Altair on the Moon with a landing accuracy that is better than 1 km (radial 95%). Preliminary performance of the Altair GN&C design, relative to this and other navigation requirements, will be given. Guidance is the onboard process that uses the estimated state vector, crew inputs, and pre-computed reference trajectories to guide both the rotational and the translational motions of the spacecraft during powered flight phases. Design objectives of reference trajectories for various mission phases vary. For example, the reference trajectory for the descent "approach" phase (the last 3-4 minutes before touchdown) will sacrifice fuel utilization efficiency in order to provide landing site visibility for both the crew and the terrain hazard detection sensor system. One output of Guidance is the steering angle commands sent to the 2 degree-of-freedom (dof) gimbal actuation system of the descent engine. The engine gimbal actuation system is controlled by a Thrust Vector Control algorithm that is designed taking into account the large quantities of sloshing liquids in tanks mounted on Altair. In this early design phase of Altair, the GN&C system is described only briefly in this paper and the emphasis is on the GN&C architecture (that is still evolving). Multiple companion papers will provide details that are related to navigation, optical navigation, guidance, fuel sloshing, rendezvous and docking, machine-pilot interactions, and others. The similarities and differences of GN&C designs for Lunar and Mars landers are briefly compared.

Lee, Allan Y.↗
NASA NTRS2013

Implementation of Kane's Method for a Spacecraft Composed of Multiple Rigid Bodies

Equations of motion are derived for a general spacecraft composed of rigid bodies connected via rotary (spherical or gimballed) joints in a tree topology. Several supporting concepts are developed in depth. Basis dyads aid in the transition from basis-free vector equations to component-wise equations. Joint partials allow abstraction of 1-DOF, 2-DOF, 3-DOF gimballed and spherical rotational joints to a common notation. The basic building block consisting of an "inner" body and an "outer" body connected by a joint enables efficient organization of arbitrary tree structures. Kane's equation is recast in a form which facilitates systematic assembly of large systems of equations, and exposes a relationship of Kane's equation to Newton and Euler's equations which is obscured by the usual presentation. The resulting system of dynamic equations is of minimum dimension, and is suitable for numerical solution by computer. Implementation is ·discussed, and illustrative simulation results are presented.

Stoneking, Eric T.↗
NASA NTRSDate not supplied

Adjusting a Full Body Model to Mitigate Inverse Kinematics Artifacts in Opensim

BACKGROUND: In support of Vibration Isolation and Stabilization (VIS) system development for Human Health Countermeasures (HHC) exercise systems in space, such as the European Enhanced Exploration Exercise Device (E4D) [1], dynamic quantities required to model the response of a proposed VIS while considering the effect of VIS motion on the forces between the human and VIS platform were obtained using motion capture data [2]. On occasion, large-amplitude oscillatory spikes were found in the subject’s linear and angular momentum derivatives, affecting analyses that depend on forces and moments derived from motion capture. The purpose of this investigation was to identify causes of these artifacts and techniques for their resolution. METHODS AND RESULTS: To obtain the required human dynamic quantities to drive the VIS simulation, motion capture data was collected containing recorded trajectories of passive retroreflective markers on body landmarks of an exercising subject. Since the full body Rajagopal model [3] was originally used to enhance gait analysis, upper body joints did not require large Ranges of Motion (ROM). We thus modified the Rajagopal model [4, 5] to allow it to be used for upper body intensive exercises like those common to the E4D. OpenSim Inverse Kinematics (IK) [6] was performed using these scaled subject models to generate the joint angles throughout the exercise while minimizing marker error. At times, the arms were observed to ‘snap’ from one configuration to another, causing spike artifacts. Following IK, a custom OpenSim plugin [7] was used to determine the required dynamic quantities including the rates of change of the linear and angular momenta of the human. Since motion capture is recorded at a larger time step than required by the VIS simulation, the human center of mass location was fit with splines and a second derivative taken to obtain the momentum derivative, allowing the VIS simulation to maintain conservation of momentum when appropriate. In a few cases during this stage, artifacts much larger than the expected noise of the second derivatives were introduced. Investigation of cases containing artifacts revealed several modifications that could be made to the OpenSim model to improve IK results. Since OpenSim models use Euler angles and rotation sequences, ‘gimbal lock’ would be encountered in the arms when raised 90 degrees to the side (e.g., T-pose, some hang clean exercise, etc.). This was resolved by reorienting the horizontal axes at the shoulder joint by 45 degrees, placing ‘gimbal lock’ outside common arm ROM, with the arm ROMs adjusted following this change. Elbow and wrist ROMs could also be adjusted to allow realistic motion while at the same time limiting the likelihood of unrealistic orientations. On occasion, the arms flipped backwards when raised above the head. This was prevented by using medial elbow markers in scaling and IK. When medial markers were not available, the acromial joint location in the unscaled model was shifted before model scaling to better align the arm with available markers. Lastly, artifacts which became apparent after taking the second derivatives of spline-fit data were found to occur in cases when the pelvis rotation limit prevented the full range of motion of an exercise. These issues were resolved by unclamping the pelvis rotation limit. Through this investigation, an understanding of conditions leading to IK artifacts was acquired allowing the automation of artifact detection. These artifact detection and mitigation techniques can be applied toward modeling of upper body motions in aerospace and other fields for improved IK results.

C A Bell↗
NASA NTRSDate not supplied

Structural Dynamics Observations in Space Launch System Green Run Hot Fire Testing

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Green Run Hot Fire (GRHF) of the SLS Core Stage provided a flight-like ground test environment for verification of integrated vehicle TVC performance. A TVC model coupled to a vehicle structural dynamic model has been developed previously and incrementally validated in subsystem tests and simulations. Still, some aspects of TVC performance in GRHF were not anticipated. The ensuing investigation demonstrated the need for well-instrumented test environments, various levels of modeling fidelity, test-representative structural models, and caution in reuse of legacy components. This paper is the sixth installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. It introduces the salient structural dynamic phenomena uncovered in ambient and hot fire testing. During the Green Run test campaign, a comparison of ambient and hot fire step responses showed a significant change in apparent damping due to the presence of friction, challenging long standing assumptions that friction could be neglected. Additionally, the characteristic response of the engine and thrust structure during GRHF proved to be more complex than anticipated, as evidenced by the available actuator, thrust structure, and engine measurements. While the string-potentiometer based test instrumentation was intended to allow for reconstruction of the engine angles along the two control axes, the geometric placement, location uncertainty, and responses in overlapping frequency spectra revealed additional phenomena requiring further analysis and post-processing. The observations from both modal and frequency response testing during the Green Run ambient and hot fire configurations led to Engine and Core Stage FEM (finite element model) updates. When evidence of unexpected engine motion was found in engine section accelerometer data, the authors pursued additional structural analysis leading to FEM updates associated with the TVC gimbal and thrust structure. Through collaboration between structures, TVC, and flight control disciplines, the test-informed models and root-cause analysis led to confident flight rationale for the first flight of the SLS launch vehicle.

Richard K. Moore↗
NASA NTRSDate not supplied

Structural Dynamics Observations in Space Launch System Green Run Hot Fire Testing

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Green Run Hot Fire (GRHF) of the SLS Core Stage provided a flight-like ground test environment for verification of integrated vehicle TVC performance. A TVC model coupled to a vehicle structural dynamic model has been developed previously and incrementally validated in subsystem tests and simulations. Still, some aspects of TVC performance in GRHF were not anticipated. The ensuing investigation demonstrated the need for well-instrumented test environments, various levels of modeling fidelity, test-representative structural models, and caution in reuse of legacy components. This paper is the sixth installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. It introduces the salient structural dynamic phenomena uncovered in ambient and hot fire testing. During the Green Run test campaign, a comparison of ambient and hot fire step responses showed a significant change in apparent damping due to the presence of friction, challenging long standing assumptions that friction could be neglected. Additionally, the characteristic response of the engine and thrust structure during GRHF proved to be more complex than anticipated, as evidenced by the available actuator, thrust structure, and engine measurements. While the string-potentiometer based test instrumentation was intended to allow for reconstruction of the engine angles along the two control axes, the geometric placement, location uncertainty, and responses in overlapping frequency spectra revealed additional phenomena requiring further analysis and post-processing. The observations from both modal and frequency response testing during the Green Run ambient and hot fire configurations led to Engine and Core Stage FEM (finite element model) updates. When evidence of unexpected engine motion was found in engine section accelerometer data, the authors pursued additional structural analysis leading to FEM updates associated with the TVC gimbal and thrust structure. Through collaboration between structures, TVC, and flight control disciplines, the test-informed models and root-cause analysis led to confident flight rationale for the first flight of the SLS launch vehicle.

Richard Moore↗
NASA NTRSDate not supplied

Core Stage TVC Systems Engineering Challenges in Reusing Heritage Hardware

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.

Thrust Vector Control↗
NASA NTRSDate not supplied

Space Launch System: Core Stage Thrust Vector Control Systems Engineering Challenges in Reusing Heritage Hardware

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of 8 mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. Two actuators are used to move each engine in two planes perpendicular to one another (i.e., pitch and yaw). The TVC system design leverages hardware from the Space Shuttle program as well as new hardware designed specifically for the Core Stage. The Space Shuttle heritage hardware directly reused on SLS includes the Orbiter TVC hydraulic servo-actuators (with two slight design modifications), the Orbiter hydraulic circulation pumps, the Orbiter gimbal block/bearing, and the Solid Rocket Booster hydraulic pumps. The Core Auxiliary Power Unit (CAPU) is derived from the Orbiter Auxiliary Power Unit (APU). The Orbiter and Solid Rocket Booster APU turbines are powered by hot gas produced by catalyzed hydrazine decomposition. On the SLS Core Stage, the CAPU turbine is spun using cold gas tapped-off from the RS-25 to CS liquid hydrogen autogenous pressurization line. While direct reuse or slight modification of existing hardware may seem to be a triple-win for a program in cost, schedule, and technical risk mitigation, those benefits can only be realized when its degree of application in a new system is carefully and thoughtfully managed. The heritage hardware reuse should be prescribed within the heritage design capability and reuse environments must lie within the envelope of heritage qualification testing. Despite the significant test and flight experience of the Shuttle heritage hardware components, successful integration with the newly designed CS TVC components and incorporation into the stage design proved to be a challenge which required re-qualification of the heritage hardware as well as thorough integrated testing to support flight certification. Examples of the challenges that were overcome include: re-qualifying heritage hardware to survive new shock and vibration environments, certifying performance of extensively modified heritage hardware, regenerating design insight due to lack of available heritage vendor data, showing compliance to modern structural design standards, translation of heritage requirements for analog avionics to modern digital avionics, and interfacing heritage mechanical hardware with newly designed avionics. This paper is the second installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. This paper will discuss several engineering challenges encountered during the development process for SLS CS TVC and how they were successfully overcome to reach flight readiness.

Thrust Vector Control↗