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NASA NTRS2010

Test Rack Development for Extended Operation of Advanced Stirling Convertors at NASA Glenn Research Center

The U.S. Department of Energy, Lockheed Martin Space Systems Company, Sunpower Inc., and NASA Glenn Research Center (GRC) have been developing an Advanced Stirling Radioisotope Generator (ASRG) for use as a power system on space science missions. This generator will make use of free-piston Stirling convertors to achieve higher conversion efficiency than with currently available alternatives. One part of NASA GRC's support of ASRG development includes extended operation testing of Advanced Stirling Convertors (ASCs) developed by Sunpower Inc. and GRC. The ASC consists of a free-piston Stirling engine integrated with a linear alternator. NASA GRC has been building test facilities to support extended operation of the ASCs for several years. Operation of the convertors in the test facility provides convertor performance data over an extended period of time. One part of the test facility is the test rack, which provides a means for data collection, convertor control, and safe operation. Over the years, the test rack requirements have changed. The initial ASC test rack utilized an alternating-current (AC) bus for convertor control; the ASRG Engineering Unit (EU) test rack can operate with AC bus control or with an ASC Control Unit (ACU). A new test rack is being developed to support extended operation of the ASC-E2s with higher standards of documentation, component selection, and assembly practices. This paper discusses the differences among the ASC, ASRG EU, and ASC-E2 test racks.

Dugala, Gina M.↗

NASA NTRS1998

Thermographic Qualification of Graphite/Epoxy Instrumentation Racks

A nondestructive evaluation method is desired for ensuring the 'as manufactured' and 'post service' quality of graphite/epoxy instrumentation rack shells. The damage tolerance and geometry of the racks dictate that the evaluation method be capable of identifying defects, as small as 0.25 inch 2 in area, over large acreage regions, tight compound radii and thickness transition zones. The primary defects of interest include voids, inclusions, delaminations and porosity. The potential for an infrared thermographic inspection to replace ultrasonic testing, for qualifying the racks as 'defect free' is under investigation. The inspection process is validated by evaluating defect standard panels built to the same specifications as the racks, except for the insertion of artificial fabricated defects. The artificial defects are designed to match those which are most prevalent in the actual instrumentation racks. A target defect area of 0.0625 inch 2 (a square with 0.25 inch on a side) was chosen for the defect standard panels to ensure the ability to find all defects of the critical (0.25 inch squared) size.

Walker, James L.↗

NASA NTRS1999

Validation of Modified Wine-Rack Thermal Design for Nickel-Hydrogen Batteries in Landsat-7 Spacecraft Thermal Vacuum Test and in Flight

A heritage wine-rack thermal/mechanical design for the nickel-hydrogen batteries was the baseline at the Landsat-7 Preliminary Design Review. An integrated thermal and power analysis of the batteries performed by the author in 1994 revealed that the maximum cell-to-cell gradient was 6.6 C. The author proposed modifying the heritage wine-rack design by enhancing heat conduction from cells to cells, and from cells to battery frame. At the 1995 Intersociety Energy Conversion Engineering Conference (IECEC), the author presented a paper on methods of modifying the wine-rack design. It showed that the modified wine-rack option, which uses a metallic filler, could reduce the maximum cell-to-cell temperature gradient to 1.30 C, and could also reduce the maximum cell temperature by as much as 80 C. That design concept was adopted by the Landsat7 Project Office, and a design change was made at the Critical Design Review. Results of the spacecraft thermal vacuum and thermal balance tests, and temperature data in flight show that the temperatures of the battery cells are very uniform. The maximum cell-to-cell gradient is 1.50 C. They validate the modified wine-rack thermal design.

Choi, Michael K.↗

NASA NTRS2000

The Interplay Between Hardware and Control System Design in the Development of the Active Rack Isolation System

A primary mission of the International Space Station (ISS) is to provide a premier microgravity laboratory environment for conducting acceleration sensitive scientific research. In order to accomplish this goal, vibroacoustic disturbances caused by station activities that occur during the microgravity mode of operation, must be controlled. In addition to source isolation and other passive isolation methods, the ISS uses active isolation at the receiver, through the use of an Active Rack Isolation System (ARIS), as part of its overall vibration isolation strategy. A schematic diagram of a typical ARIS payload rack is shown. The ARIS isolation control system senses rack acceleration via three triaxial accelerometer heads and uses eight pushrod actuators to perform active vibration attenuation. Position sensors housed in the actuator assembly are used to sense the relative position between the rack and the station. Electrical power, data and other essential resources are routed through a set of umbilicals that interface with a passthrough panel at the bottom of the rack. A representative umbilical set is shown.

Fialho, Ian J.↗

NASA NTRS2014

Conducting Research on the International Space Station Using the EXPRESS Rack Facilities

EXPRESS Racks provide capability for payload access to ISS resources. The successful on-orbit operations and versatility of the EXPRESS Rack has facilitated the operations of many scientific areas, with the promise of continued payload support for years to come. EXPRESS Racks are currently deployed in the US Lab, Columbus and JEM. Process improvements and enhancements continue to improve the accommodations and make the integration and operations process more efficient. Payload Integration Managers serve as the primary interface between the ISS Program and EXPRESS Payload Developers. EXPRESS Project coordinates across multiple functional areas and organizations to ensure integrated EXPRESS Rack and subrack products and hardware are complete, accurate, on time, safe, and certified for flight. NASA is planning to expand the EXPRESS payload capacity by developing new Basic Express Racks expected to be on ISS in 2018.

Thompson, Sean W.↗

NASA NTRS2015

Design, Fabrication, and Testing of a Composite Rack Prototype in Support of the Deep Space Habitat Program

In support of the Deep Space Habitat project a number of composite rack prototypes were developed, designed, fabricated and tested to various extents ( with the International Standard Payload Rack configuration, or crew quarters, as a baseline). This paper focuses specifically on a composite rack prototype with a direct tie in to Space Station hardware. The outlined prototype is an all composite construction, excluding metallic fasteners, washers, and their associated inserts. The rack utilizes braided carbon composite tubing for the frame with the sidewalls, backwall and flooring sections utilizing aircraft grade composite honeycomb sandwich panels. Novel additively manufactured thermoplastic joints and tube inserts were also developed in support of this effort. Joint and tube insert screening tests were conducted at a preliminary level. The screening tests allowed for modification, and enhancement, of the fabrication and design approaches, which will be outlined. The initial joint tests did not include mechanical fasteners. Adhesives were utilized at the joint to composite tube interfaces, along with mechanical fasteners during final fabrication (thus creating a stronger joint than the adhesive only variant). In general the prototype was focused on a potential in-space assembly approach, or kit-of-parts construction concept, which would not necessarily require the inclusion of an adhesive in the joint regions. However, given the tie in to legacy Station hardware (and potential flight loads with imbedded hardware mass loadings), the rack was built as stiff and strong as possible. Preliminary torque down tests were also conducted to determine the feasibility of mounting the composite honeycomb panels to the composite tubing sections via the additively manufactured tube inserts. Additional fastener torque down tests were also conducted with inserts (helicoils) imbedded within the joints. Lessons learned are also included and discussed.

Smith, Russ↗

NASA NTRS1977

Integrated payload and mission planning, phase 3. Volume 4: Optimum utilization of Spacelab racks and pallets

The methodology to optimize the utilization of Spacelab racks and pallets and to apply this methodology to the early STS Spacelab missions was developed. A review was made of Spacelab Program requirements and flow plans, generic flow plans for racks and pallets were examined, and the principal optimization criteria and methodology were established. Interactions between schedule, inventory, and key optimization factors; schedule and cost sensitivity to optional approaches; and the development of tradeoff methodology were addressed. This methodology was then applied to early spacelab missions (1980-1982). Rack and pallet requirements and duty cycles were defined, a utilization assessment was made, and several trade studies performed involving varying degrees of Level IV integration, inventory level, and shared versus dedicated Spacelab racks and pallets.

Logston, R. G.↗

NASA NTRS2000

Validation of a "Kane's Dynamics" Model for the Active Rack Isolation System

Many microgravity space-science experiments require vibratory acceleration levels unachievable without active isolation. The Boeing Corporation's Active Rack Isolation System (ARIS) employs a novel combination of magnetic actuation and mechanical linkages, to address these isolation requirements on the International Space Station (ISS). ARIS provides isolation at the rack (international Standard Payload Rack, or ISPR) level. Effective model-based vibration isolation requires (1) an isolation device, (2) an adequate dynamic (i.e., mathematical) model of that isolator, and (3) a suitable, corresponding controller, ARIS provides the ISS response to the first requirement. In November 1999, the authors presented a response to the second ("A 'Kane's Dynamics' model for the Active Rack Isolation System", Hampton and Beech) intended to facilitate an optimal-controls approach to the third. This paper documents the validation of that high-fidelity dynamic model of ARIS. As before, this model contains the full actuator dynamics, however, the umbilical models are not included in this presentation. The validation of this dynamics model was achieved by utilizing two Commercial Off the Shelf (COTS) software tools: Deneb's ENVISION, and Online Dynamics' AUTOLEV. ENVISION is a robotics software package developed for the automotive industry that employs 3-dimensional (3-D) Computer Aided Design (CAD) models to facilitate both forward and inverse kinematics analyses. AUTOLEV is a DOS based interpreter that is designed in general to solve vector based mathematical problems and specifically to solve Dynamics problems using Kane's method.

Beech, Geoffrey S.↗

NASA NTRS2000

The Fluids And Combustion Facility Combustion Integrated Rack And The Multi-User Droplet Combustion Apparatus: Microgravity Combustion Science Using Modular Multi-User Hardware

The Fluids and Combustion Facility (FCF) is a multi-rack payload planned for the International Space Station (ISS) that will enable the study of fluid physics and combustion science in a microgravity environment. The Combustion Integrated Rack (CIR) is one of two International Standard Payload Racks of the FCF and is being designed primarily to support combustion science experiments. The Multi-user Droplet Combustion Apparatus (MDCA) is a multi-user apparatus designed to accommodate four different droplet combustion science experiments and is the first payload for CIR. The CIR will function independently until the later launch of the Fluids Integrated Rack component of the FCF. This paper provides an overview of the capabilities and the development status of the CIR and MDCA.

OMalley, Terence F.↗

NASA NTRS2005

Rack Distribution Effects on MPLM Center of Mass

This research was in support of exploring the need for more flexible "center of gravity (CG) specifications than those currently established by NASA for the Multi-Purpose Logistics Module (MPLM). The MPLM is the cargo carrier for International Space Station (ISS) missions. The MPLM provides locations for 16 standard racks, as shown in Figure 1; not all positions need to be filled in any given flight. The MPLM coordinate system (X(sub M), Y(sub M), Z(sub M)) is illustrated as well. For this project, the primary missions of interest were those which supply the ISS and remove excess materials on the return flights. These flights use a predominate number of "Resupply Stowage Racks" (RSR) and "Resupply Stowage Platforms" (RSP). In these two types of racks, various smaller items are stowed. Hence, these racks will exhibit a considerable range of mass values as well as a range as to where their individual CG are located.

Tester, John T.↗

NASA NTRS2007

Space Station and Shuttle Payloads: Rack Insertion Device Pneumatic Assembly Setup and Test

As part of my KSC summer internship, I was given the very cool task of writing a test preparation sheet (TPS). A TPS is a set of instructions for certain procedures or tasks, and serves as the documentation for the tasks. TPSs guide task leaders and technicians throughout the work procedures, safely, informing them of what steps will be hazardous, what precautions must be taken, and what to do in the case of an accident or emergency. I was placed in Boeing's Resupply & Return Division (R&R). R&R is responsible for sending up food and supplies to the International Space Station (ISS) with the use of three Italian Multi Purpose Logistics Modules - Leonardo, Donatello, and Raffaello. The supplies are loaded into Resupply Stowage Racks (RSRs) or Resupply Stowage Platforms (RSPs) (though, both are usually referred to as racks), depending on their size and shape. These racks are loaded into the modules with the help of a specialized crane known as the Rack Insertion Device (RID). The RID rests on four pneumatic air jacks, these allow for an operator to raise or lower the RID. The pneumatic air system supplies the air jacks with the necessary air pressure required to lift the RID.

Conde, Nathan↗

NASA NTRS1985

Laboratory glassware rack for seismic safety

A rack for laboratory bottles and jars for chemicals and medicines has been designed to provide the maximum strength and security to the glassware in the event of a significant earthquake. The rack preferably is rectangular and may be made of a variety of chemically resistant materials including polypropylene, polycarbonate, and stainless steel. It comprises a first plurality of parallel vertical walls, and a second plurality of parallel vertical walls, perpendicular to the first. These intersecting vertical walls comprise a self-supporting structure without a bottom which sits on four legs. The top surface of the rack is formed by the top edges of all the vertical walls, which are not parallel but are skewed in three dimensions. These top edges form a grid matrix having a number of intersections of the vertical walls which define a number of rectangular compartments having varying widths and lengths and varying heights.

Cohen, M. M.↗

NASA NTRS1991

Mini-rack testbed evaluation

The goal was to characterize the Health Maintenance Facility (HMF)-like mini-racks and drawers onboard the KC-135 as a test bed for the Space Station Freedom HMF racks. An additional goal was to evaluate the attachments, mounting points, and inner drawer assemblies of the mini-racks for various medical equipment and supplies. Results and recommendations are given.

Gosbee, John↗

NASA NTRS1993

Rack Insertion End Effector (RIEE) automation

NASA is developing a mechanism to manipulate and insert Racks into the Space Station Logistic modules. The mechanism consists of the following: a base with three motorized degrees of freedom, a 3 section motorized boom that goes from 15 to 44 feet in length, and a Rack Insertion End Effector (RIEE) with 5 hand wheels for precise alignment. The robotics section was tasked with the automation of the RIEE unit. In this report, for the automation of the RIEE unit, application of the Perceptics Vision System was conceptually developed to determine the position and orientation of the RIEE relative to the logistic module, and a MathCad program is written to display the needed displacements for precise alignment and final insertion of the Rack. The uniqueness of this report is that the whole report is in fact a MathCad program including text, derivations, and executable equations with example inputs and outputs.

Malladi, Narasimha↗

NASA NTRS1994

Rack Insertion End Effector (RIEE) guidance

NASA-KSC has developed a mechanism to handle and insert Racks into the Space Station Logistic Modules. This mechanism consists of a Base with 3 motorized degrees of freedom, a 3 section motorized Boom that goes from 15 to 44 feet in length, and a Rack Insertion End Effector (RIEE) with 5 hand wheels for precise alignment. During the 1993 NASA-ASEE Summer Faculty Fellowship Program at KSC, I designed an Active Vision (Camera) Arrangement and developed an algorithm to determine (1) the displacements required by the Room for its initial positioning and (2) the rotations required at the five hand-wheels of the RIEE, for the insertion of the Rack, using the centroids fo the Camera Images of the Location Targets in the Logistic Module. Presently, during the summer of '94, I completed the preliminary design of an easily portable measuring instrument using encoders to obtain the 3-Dimensional Coordinates of Location Targets in the Logistics Module relative to the RIEE mechanism frame. The algorithm developed in '93 can use the output of this instrument also. Simplification of the '93 work and suggestions for the future work are discussed.

Malladi, Narasimha S.↗

NASA NTRS1999

A "Kanes's Dynamics" Model for the Active Rack Isolation System

Hampton, R. David↗

NASA NTRS2000

The Life Cycle Application of Intelligent Software Modeling for the First Materials Science Research Rack

Marshall Space Flight Center (MSFC) has been funding development of intelligent software models to benefit payload ground operations for nearly a decade. Experience gained from simulator development and real-time monitoring and control is being applied to engineering design, testing, and operation of the First Material Science Research Rack (MSRR-1). MSRR-1 is the first rack in a suite of three racks comprising the Materials Science Research Facility (MSRF) which will operate on the International Space Station (ISS). The MSRF will accommodate advanced microgravity investigations in areas such as the fields of solidification of metals and alloys, thermo-physical properties of polymers, crystal growth studies of semiconductor materials, and research in ceramics and glasses. The MSRR-1 is a joint venture between NASA and the European Space Agency (ESA) to study the behavior of different materials during high temperature processing in a low gravity environment. The planned MSRR-1 mission duration is five (5) years on-orbit and the total design life is ten (IO) years. The MSRR-1 launch is scheduled on the third Utilization Flight (UF-3) to ISS, currently in February of 2003). The objective of MSRR-1 is to provide an early capability on the ISS to conduct material science, materials technology, and space product research investigations in microgravity. It will provide a modular, multi-user facility for microgravity research in materials crystal growth and solidification. An intelligent software model of MSRR-1 is under development and will serve multiple purposes to support the engineering analysis, testing, training, and operational phases of the MSRR-1 life cycle development. The G2 real-time expert system software environment developed by Gensym Corporation was selected as the intelligent system shell for this development work based on past experience gained and the effectiveness of the programming environment. Our approach of multi- uses of the simulation model and its intuitive graphics capabilities is providing a concurrent engineering environment for rapid prototyping and development. Operational schematics of the MSRR-1 electrical, thermal control, vacuum access, and gas supply systems, and furnace inserts are represented graphically in the environment. Logic to represent first order engineering calculations is coded into the knowledge base to simulate the operational behavior of the MSRR-1 systems. An example of engineering data provided includes electrical currents, voltages, operational power, temperatures, thermal fluid flow rates. pressures, and component status indications. These type of data are calculated and displayed at appropriate instrumentation points, and the schematics are animated to reflect the simulated operational status of the MSRR-1. The software control functions are also simulated to represent appropriate operational behavior based on automated control and response to commands received by the crew or ground controllers. The first benefit of this simulation environment is being realized in the high fidelity engineering analysis results from the electrical power system G2 model. Secondly, the MSRR-1 simulation model will be embedded with a hardware mock-up of the MSRR-1 to provide crew training on MSRR-1 integrated payload operations. G2 gateway code will output the simulated instrumentation values, termed as telemetry, in a flight-like data stream so that the crew has realistic and accurate simulated MSRR-1 data on the flight displays which will be designed for crew use. The simulation will also respond appropriately to crew or ground initiated commands, which will be part of normal facility operations. A third use of the G2 model is being planned; the MSRR-1 simulation will be integrated with additional software code as part of the test configuration of the primary onboard computer, or Master Controller, for MSRR-1. We will take advantage of the G2 capability to simulate the flight like data stream to test flight software responses and behavior. A fourth use of the G2 model will be to train the Ground Support Personnel that will monitor the MSRR-1 systems and payloads while they are operating aboard the ISS. The intuitive, schematic based environment will provide an excellent foundation for personnel to understand the integrated configuration and operation of the MSRR-1, and the anticipated telemetry feedback based on operational modes of the equipment. Expert monitoring features will be enhanced to provide a smart monitoring environment for the operators. These features include: (1) Animated, intuitive schematic-based displays which reflect telemetry values, (1) Real-time plotting of simulated or incoming sensor values, (3) High/Low exception monitoring for analog data, (4) Expected state monitoring for discrete data, (5) Data trending, (6) Automated malfunction procedure execution to diagnose problems, (7) Look ahead capability to planned MSRR-1 activities in the onboard timeline. And finally, the logic to calculate telemetry values will be deactivated, and the same environment will interface to the incoming data for the real-time telemetry stream to schematically represent the onboard hardware configuration. G2 will be the foundation for the real-time monitoring and control environment. In summary, our MSRR-1 simulation model spans many elements of the life cycle development of this project: Engineering Analysis, Test and Checkout, Training of Crew and Ground Personnel, and Real-time monitoring and control. By utilizing the unique features afforded by an expert system development environment, we have been able to synergize a powerful tool capable of addressing our project needs at every phase of project development.

Rice, Amanda↗

NASA NTRS2001

CM-2 Environmental / Modal Testing of Spacehab Racks

Combined environmental/modal vibration testing has been implemented at the NASA Glenn Research Center's Structural Dynamics Laboratory. The benefits of combined vibration testing are that it facilitates test article modal characterization and vibration qualification testing. The Combustion Module-2 (CM-2) is a space experiment that launches on Shuttle mission STS 107 in the SPACEHAB Research Double Module. The CM-2 flight hardware is integrated into a SPACEHAB single and double rack. CM-2 rack level combined vibration testing was recently completed on a shaker table to characterize the structure's modal response and verify the random vibration response. Control accelerometers and limit force gauges, located between the fixture and rack interface, were used to verify the input excitation. Results of the testing were used to verify the loads and environments for flight on the Shuttle.

McNelis, Mark E.↗