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NASA NTRS2022

Advanced Lightweight Metallic Fuselage Project Manufacturing Trade Study

Recent advances in large-scale flow forming of integrally stiffened cylinders (ISCs) have motivated evaluation of available technologies for rapid manufacturing of metallic fuselages. The current state-of-the-art in flow forming of ISCs produces 10-ft. diameter, 5-ft. long barrels with integral longitudinal blade stiffeners, and these single-piece ISCs are produced in approximately 1.5 hours. While other manufacturing processes are required to incorporate additional structural elements (ASE) such as circumferential ring frames, reinforcements around window and door cut-outs, and floors to the ISCs to complete the fuselage structure, flow forming technology may assist the aerospace industry in meeting manufacturing rate demands. In order to evaluate this technology, a fuselage manufacturing demonstration article (MDA) fabricated from two ISCs is scheduled for fabrication and delivery to NASA Langley Research Center (LaRC) by the end of 2022. In this study, eight manufacturing technologies were assessed to downselect candidate manufacturing processes for adding ASE to complete the MDA. A literature review and evaluation of contractor-produced panels covering a spectrum of welding and additive manufacturing (AM) processes were conducted at NASA LaRC. The analytical hierarchy process (AHP) was used to evaluate figures of merit (FOMs) for selecting manufacturing process(es) to integrate ASE with the ISCs to form a fuselage MDA. The AHP results revealed that scalability, structural performance, and distortion control were the most valued criteria for downselecting the manufacturing process to construct the internal stiffening structures. Based on the FOMs, this study concluded that a welding process is best suited for integrating the majority of the ASE, namely the circumferential ring frames. All of the welding processes received higher scores than AM processes due to higher maturity, higher structural performance, fewer post-processing requirements in machining and heat treating, and faster deposition rates. Among the welding processes, cold metal transfer (CMT) welding was ranked the most favorable process for assembling the MDA, with the other welding processes (laser welding (LW), friction stir welding (FSW), and refill friction stir spot welding (RFSSW)) scoring slightly lower. This was a consequence of the perceived maturity of the CMT welding process and its relatively high structural performance and low distortion resulting from the low heat input. Among the AM processes, CMT AM showed the greatest promise due to benefits derived from its scalability, lower 1st order process complexity, and low distortion. The AM processes may have potential for select applications, such as adding structural reinforcements around window and door cut-outs, but are not considered optimal for integrating the entire MDA.

Manufacturing↗

NASA NTRSDate not supplied

A Proposed Clock Synchronization Method for the Solar System Internet

Networked communications in space are necessary to achieve scalability in terms of the number of communicating nodes but also in terms of the overall system complexity. A key component to such a system is the ability to synchronize clocks, which is the focus of this paper. The so-called Solar System Internet (SSI) will be built upon Delay Tolerant Networking (DTN), which, in analogy to the Internet Protocol (IP), can be considered a suite of protocols necessary for networking in the space domain. Therefore, our goal is to extend this suite to include a DTN clock synchronization capability, analogous to the Network Time Protocol (NTP) used in the Internet. A motivating example of a network in space is NASA’s LunaNet, a vision for a multi-hop multi-path network extending to the moon wherein not all nodes will have direct connections to an authoritative reference clock. In this paper, we propose a general clock synchronization methodology and algorithm that could be used for LunaNet as well as more elaborate time-varying networks. In recent years, DTN has benefited from modeling efforts founded on the mathematical tool of sheaves. Here we continue this work to provide an approach to clock synchronization. Due to the time-varying nature of space networks, absolute consensus is not possible. However, the sheaf Laplacian provides a practical, distributed approach to approximating consensus by allowing data to diffuse through the network. In particular, the sheaf Laplacian is readily computable, lending our approach to implementation. Our approach is well suited to handle the difficulties of space networks. For instance, differences in clock accuracy mean certain nodes are more authoritative than others; we can account for these differences through hierarchies in the network, generalizing the strata in NTP. Furthermore, just as error estimation is an integral part of NTP, we are able to give concrete error bounds for our approach. Indeed, different applications (e.g., communications schedules, pointing, navigation, distributed science) will have different requirements, hence it is necessary to maintain clocks within a given tolerance. We outline some of the necessary steps to turn our approach into a practical network protocol that could be used in DTN, and we conclude the paper with suggestions for future research.

Michael Moy↗

NASA NTRS2008

Evaluation of Advanced Composite Structures Technologies for Application to NASA's Vision for Space Exploration

An assessment was performed to identify the applicability of composite material technologies to major structural elements of the NASA Constellation program. A qualitative technology assessment methodology was developed to document the relative benefit of 24 structural systems with respect to 33 major structural elements of Ares I, Orion, Ares V, and Altair. Technology maturity assessments and development plans were obtained from more than 30 Boeing subject matter experts for more than 100 technologies. These assessment results and technology plans were combined to generate a four-level hierarchy of recommendations. An overarching strategy is suggested, followed by a Constellation-wide development plan, three integrated technology demonstrations, and three focused projects for a task order follow-on.

Messinger, Ross↗

NASA NTRS2004

Fragmentation hierarchy of bright sungrazing comets and the birth and orbital evolution of the Kreutz system. I. Two-superfragment model

A back-and-forth orbit integration technique, developed for our previous investigation of the splitting of the parent of the sungrazers C/1882 R1 and C/1965 S1, is now applied in an effort to understand the history and orbital evolution of the Kreutz sungrazer system, starting with the birth of two subgroups, which show prominently among the bright members and whose inception dates back to the progenitor's breakup into two superfragments. The integration technique is used to reproduce the motion of comet C/1843 D1 - the second brightest sungrazer known and presumably the most massive surviving piece of superfragment I - from the motion of C/1882 R1 - the brightest sungrazer on record and arguably the most massive surviving piece of superfragment II. Running the orbit of C/1882 R1 back to A.D. 326, the progenitor comet is found to have split at a heliocentric distance of 50 AU and nearly 30 yr before perihelion. The superfragments acquired separation velocities of similar to8 m s(-1) in opposite directions. Using the same technique, we show next that (1) the motions of two additional sungrazers, C/1880 C1 and C/1887 B1, are matched extremely well if these objects shared a common parent with C/1843 D1, and (2) C/1963 R1 (Pereyra), the second brightest subgroup I member on record, is more closely related to subgroup II objects (such as C/1882 R1 and C/1965 S1) than to C/1843 D1. This finding raises serious doubts about the major role of the subgroups in the system's orbital history and offers an incentive for considering an alternative dynamical scenario. The fragmentation models for C/1963 R1 and two additional bright sungrazers, C/1945 X1 and C/1970 K1, suggest that (1) these comets may have been the most massive pieces of the fragment populations formed from their respective disintegrating parents, and (2) the course of evolution of the Kreutz system at the upper end of the mass spectrum may be better ascertained from the distribution of the sungrazers' arrival times than from the sources of subgroups. If so, the fragment hierarchy should be determined primarily by the cascading nature of the fragmentation process, which was recently shown by Sekanina to control the evolution of minor fragments as well. The sungrazer system's estimated age is in any case very short, less than 1700 yr.

sungrazing comets↗

NASA NTRS1990

Data storage technology comparisons

The role of data storage and data storage technology is an integral, though conceptually often underestimated, portion of data processing technology. Data storage is important in the mass storage mode in which generated data is buffered for later use. But data storage technology is also important in the data flow mode when data are manipulated and hence required to flow between databases, datasets and processors. This latter mode is commonly associated with memory hierarchies which support computation. VLSI devices can reasonably be defined as electronic circuit devices such as channel and control electronics as well as highly integrated, solid-state devices that are fabricated using thin film deposition technology. VLSI devices in both capacities play an important role in data storage technology. In addition to random access memories (RAM), read-only memories (ROM), and other silicon-based variations such as PROM's, EPROM's, and EEPROM's, integrated devices find their way into a variety of memory technologies which offer significant performance advantages. These memory technologies include magnetic tape, magnetic disk, magneto-optic disk, and vertical Bloch line memory. In this paper, some comparison between selected technologies will be made to demonstrate why more than one memory technology exists today, based for example on access time and storage density at the active bit and system levels.

Katti, Romney R.↗

NASA NTRS1972

Development of STOLAND, a versatile navigation, guidance and control system.

STOLAND has been developed to perform navigation, guidance, control, and flight management experiments in advanced V/STOL aircraft. An integrated digital concept using modern avionics components was selected as the simplest approach to maximizing versatility and growth potential. Unique flexibility has been obtained by use of a single, general-purpose digital computer for all navigation, guidance, control, and displays computation. Modularity of the software insures easy change of experiments. The general-purpose computer is integrated with flexible pilot controls and with both electromechanical and CRT displays for maximum cockpit versatility. A complex hierarchy of control modes with safety monitors and interlocks has been provided.

Hansen, Q. M.↗

NASA NTRS2019

Evaluation of Classifier Complexity for Delay Tolerant Network Routing

The growing popularity of small cost effective satellites (SmallSats, CubeSats, etc.) creates the potential for a variety of new science applications involving multiple nodes functioning together or independently to achieve a task, such as swarms and constellations. As this technology develops and is deployed for missions in Low Earth Orbit and beyond, the use of delay tolerant networking (DTN) techniques may improve communication capabilities within the network. In this paper, a network hierarchy is developed from heterogeneous networks of SmallSats, surface vehicles, relay satellites and ground stations which form an integrated network. There is a tradeoff between complexity, flexibility, and scalability of user defined schedules versus autonomous routing as the number of nodes in the network increases. To address these issues, this work proposes a machine learning classifier based on DTN routing metrics. A framework is developed which will allow for the use of several categories of machine learning algorithms (decision tree, random forest and deep learning) to be applied to a dataset of historical network statistics, which allows for the evaluation of algorithm complexity versus performance to be explored. We develop the emulation of a hierarchical network, consisting of tens of nodes which form a cognitive network architecture. CORE (Common Open Research Emulator) is used to emulate the network using bundle protocol and DTN IP neighbor discovery.

Dudukovich, Rachel↗

NASA NTRS1987

Development and application of unified algorithms for problems in computational science

A framework is presented for developing computationally unified numerical algorithms for solving nonlinear equations that arise in modeling various problems in mathematical physics. The concept of computational unification is an attempt to encompass efficient solution procedures for computing various nonlinear phenomena that may occur in a given problem. For example, in Computational Fluid Dynamics (CFD), a unified algorithm will be one that allows for solutions to subsonic (elliptic), transonic (mixed elliptic-hyperbolic), and supersonic (hyperbolic) flows for both steady and unsteady problems. The objectives are: development of superior unified algorithms emphasizing accuracy and efficiency aspects; development of codes based on selected algorithms leading to validation; application of mature codes to realistic problems; and extension/application of CFD-based algorithms to problems in other areas of mathematical physics. The ultimate objective is to achieve integration of multidisciplinary technologies to enhance synergism in the design process through computational simulation. Specific unified algorithms for a hierarchy of gas dynamics equations and their applications to two other areas: electromagnetic scattering, and laser-materials interaction accounting for melting.

Shankar, Vijaya↗

NASA NTRS1987

NASA B737 flight test results of the total energy control system

The Total Energy Control System (TECS) is an integrated autopilot/autothrottle developed by BCAC that was test flown on NASA Langley's Transport System Research Vehicle (i.e., a highly modified Boeing B737). This systems was developed using principles of total energy in which the total kinetic and potential energy of the airplane was controlled by the throttles, and the energy distribution controled by the elevator. TECS integrates all the control functions of a conventional pitch autopilot and autothrottle into a single generalized control concept. This integration provides decoupled flightpath and maneuver control, as well as a coordinated throttle response for all maneuvers. A mode hierarchy was established to preclude exceeding airplane safety and performance limits. The flight test of TECS took place as a series of five flights over a 33-week period during September 1985 at NASA Langley. Most of the original flight test plan was completed within the first three flights with the system not exhibiting any instabilities or design problems that required any gain adjustment during flight.

Bruce, Kevin R.↗

NASA NTRS1992

Integrated health monitoring and controls for rocket engines

Current research in intelligent control systems at the Lewis Research Center is described in the context of a functional framework. The framework is applicable to a variety of reusable space propulsion systems for existing and future launch vehicles. It provides a 'road map' technology development to enable enhanced engine performance with increased reliability, durability, and maintainability. The framework hierarchy consists of a mission coordination level, a propulsion system coordination level, and an engine control level. Each level is described in the context of the Space Shuttle Main Engine. The concept of integrating diagnostics with control is discussed within the context of the functional framework. A distributed real time simulation testbed is used to realize and evaluate the functionalities in closed loop.

Merrill, W. C.↗

NASA NTRS1992

Integrated health monitoring and controls for rocket engines

Merrill, W. C.↗

NASA NTRS1998

The Software Design for the Wide-Field Infrared Explorer Attitude Control System

The Wide-Field Infrared Explorer (WIRE), currently scheduled for launch in September 1998, is the fifth of five spacecraft in the NASA/Goddard Small Explorer (SMEX) series. This paper presents the design of WIRE's Attitude Control System flight software (ACS FSW). WIRE is a momentum-biased, three-axis stabilized stellar pointer which provides high-accuracy pointing and autonomous acquisition for eight to ten stellar targets per orbit. WIRE's short mission life and limited cryogen supply motivate requirements for Sun and Earth avoidance constraints which are designed to prevent catastrophic instrument damage and to minimize the heat load on the cryostat. The FSW implements autonomous fault detection and handling (FDH) to enforce these instrument constraints and to perform several other checks which insure the safety of the spacecraft. The ACS FSW implements modules for sensor data processing, attitude determination, attitude control, guide star acquisition, actuator command generation, command/telemetry processing, and FDH. These software components are integrated with a hierarchical control mode managing module that dictates which software components are currently active. The lowest mode in the hierarchy is the 'safest' one, in the sense that it utilizes a minimal complement of sensors and actuators to keep the spacecraft in a stable configuration (power and pointing constraints are maintained). As higher modes in the hierarchy are achieved, the various software functions are activated by the mode manager, and an increasing level of attitude control accuracy is provided. If FDH detects a constraint violation or other anomaly, it triggers a safing transition to a lower control mode. The WIRE ACS FSW satisfies all target acquisition and pointing accuracy requirements, enforces all pointing constraints, provides the ground with a simple means for reconfiguring the system via table load, and meets all the demands of its real-time embedded environment (16 MHz Intel 80386 processor with 80387 coprocessor running under the VRTX operating system). The mode manager organizes and controls all the software modules used to accomplish these goals, and in particular, the FDH module is tightly coupled with the mode manager.

Anderson, Mark O.↗

NASA NTRS2008

RHSEG and Subdue: Background and Preliminary Approach for Combining these Technologies for Enhanced Image Data Analysis, Mining and Knowledge Discovery

Under a project recently selected for funding by NASA's Science Mission Directorate under the Applied Information Systems Research (AISR) program, Tilton and Cook will design and implement the integration of the Subdue graph based knowledge discovery system, developed at the University of Texas Arlington and Washington State University, with image segmentation hierarchies produced by the RHSEG software, developed at NASA GSFC, and perform pilot demonstration studies of data analysis, mining and knowledge discovery on NASA data. Subdue represents a method for discovering substructures in structural databases. Subdue is devised for general-purpose automated discovery, concept learning, and hierarchical clustering, with or without domain knowledge. Subdue was developed by Cook and her colleague, Lawrence B. Holder. For Subdue to be effective in finding patterns in imagery data, the data must be abstracted up from the pixel domain. An appropriate abstraction of imagery data is a segmentation hierarchy: a set of several segmentations of the same image at different levels of detail in which the segmentations at coarser levels of detail can be produced from simple merges of regions at finer levels of detail. The RHSEG program, a recursive approximation to a Hierarchical Segmentation approach (HSEG), can produce segmentation hierarchies quickly and effectively for a wide variety of images. RHSEG and HSEG were developed at NASA GSFC by Tilton. In this presentation we provide background on the RHSEG and Subdue technologies and present a preliminary analysis on how RHSEG and Subdue may be combined to enhance image data analysis, mining and knowledge discovery.

Tilton, James C.↗

NASA NTRS2019

High-Resolution, Lightweight, and Low-cost X-Ray Optics for the Lynx Observatory

We describe an approach to build an x-ray mirror assembly that can meet Lynx’s requirements of high-angular resolution, large effective area, light weight, short production schedule, and low-production cost. Adopting a modular hierarchy, the assembly is composed of 37,492 mirror segments, each of which measures ∼100 mm × 100 mm × 0.5 mm. These segments are integrated into 611 modules, which are individually tested and qualified to meet both science performance and spaceflight environment requirements before they in turn are integrated into 12 metashells. The 12 metashells are then integrated to form the mirror assembly. This approach combines the latest precision polishing technology and the monocrystalline silicon material to fabricate the thin and lightweight mirror segments. Because of the use of commercially available equipment and material and because of its highly modular and hierarchical building-up process, this approach is highly amenable to automation and mass production to maximize production throughput and to minimize production schedule and cost. As of fall 2018, the basic elements of this approach, including substrate fabrication, coating, alignment, and bonding, have been validated by the successful building and testing of single-pair mirror modules. In the next few years, the many steps of the approach will be refined and perfected by repeatedly building and testing mirror modules containing progressively more mirror segments to fully meet science performance, spaceflight environments, as well as programmatic requirements of the Lynx mission and other proposed missions, such as AXIS.

Zhang, William W.↗

NASA NTRS1983

Hierarchical Design and Verification for VLSI

The specification and verification work is described in detail, and some of the problems and issues to be resolved in their application to Very Large Scale Integration VLSI systems are examined. The hierarchical design methodologies enable a system architect or design team to decompose a complex design into a formal hierarchy of levels of abstraction. The first step inprogram verification is tree formation. The next step after tree formation is the generation from the trees of the verification conditions themselves. The approach taken here is similar in spirit to the corresponding step in program verification but requires modeling of the semantics of circuit elements rather than program statements. The last step is that of proving the verification conditions using a mechanical theorem-prover.

Shostak, R. E.↗

NASA NTRSDate not supplied

Exploitation of a Validation Hierarchy for Modeling and Simulation

Across engineering there is an evolving need to increase reliance on physics-based simulation to develop, design and optimize engineering systems. This increased reliance on modeling and simulation has highlighted a growing need to transform the confidence that modeling and simulation analysts have in their results into credibility for systems engineers to design and field systems more quickly and with less physical testing. For isolated components of a complex system, where a single discipline may drive product design, this is less of a concern as the relationship is often straightforward and easy to explain. However, when these isolated components are integrated, and are expected to operate in a multi-disciplinary context in which safety critical systems are involved, new concepts and model assurance standards are required. In this paper we address this challenge by showing how a model validation hierarchy can be exploited to identify those model validation experiments that will contribute most to increasing confidence and credibility of modeling and simulation predictions. The approach that is adopted contains four main steps. The first step is the construction of a model validation hierarchy that links subsystems, assemblies, and components to a hierarchy of physical experiments that can be used support model validation. This hierarchy connects the concerns of systems engineers to those of the modeling and simulation analyst in a clear and logical way. The structure and content of this hierarchy is then used in a second step to establish which physical phenomena have the greatest impact on overall system performance metrics. A gap analysis technique, based upon modeling and simulation concerns, is then used to prioritize the important physical phenomenon. Unfortunately, a common outcome of such gap analyses is the identification of many important gaps and so, in the final step of our process, we advocate the use of a global sensitivity analysis as a means to complete the prioritization.

Verification and Validation↗

NASA NTRSDate not supplied

Exploitation of a Validation Hierarchy for Modeling and Simulation

Verification and Validation↗

NASA NTRS2004

An Architecture for Intelligent Systems Based on Smart Sensors

Based on requirements for a next-generation rocket test facility, elements of a prototype Intelligent Rocket Test Facility (IRTF) have been implemented. A key component is distributed smart sensor elements integrated using a knowledgeware environment. One of the specific goals is to imbue sensors with the intelligence needed to perform self diagnosis of health and to participate in a hierarchy of health determination at sensor, process, and system levels. The preliminary results provide the basis for future advanced development and validation using rocket test stand facilities at Stennis Space Center (SSC). We have identified issues important to further development of health-enabled networks, which should be of interest to others working with smart sensors and intelligent health management systems.

Schmalzel, John↗