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NASA NTRS2013

Design of Test Support Hardware for Advanced Space Suits

As a member of the Space Suit Assembly Development Engineering Team, I designed and built test equipment systems to support the development of the next generation of advanced space suits. During space suit testing it is critical to supply the subject with two functions: (1) cooling to remove metabolic heat, and (2) breathing air to pressurize the space suit. The objective of my first project was to design, build, and certify an improved Space Suit Cooling System for manned testing in a 1‐G environment. This design had to be portable and supply a minimum cooling rate of 2500 BTU/hr. The Space Suit Cooling System is a robust, portable system that supports very high metabolic rates. It has a highly adjustable cool rate and is equipped with digital instrumentation to monitor the flowrate and critical temperatures. It can supply a variable water temperature down to 34 deg., and it can generate a maximum water flowrate of 2.5 LPM. My next project was to design and build a Breathing Air System that was capable of supply facility air to subjects wearing the Z‐2 space suit. The system intakes 150 PSIG breathing air and regulates it to two operating pressures: 4.3 and 8.3 PSIG. It can also provide structural capabilities at 1.5x operating pressure: 6.6 and 13.2 PSIG, respectively. It has instrumentation to monitor flowrate, as well as inlet and outlet pressures. The system has a series of relief valves to fully protect itself in case of regulator failure. Both projects followed a similar design methodology. The first task was to perform research on existing concepts to develop a sufficient background knowledge. Then mathematical models were developed to size components and simulate system performance. Next, mechanical and electrical schematics were generated and presented at Design Reviews. After the systems were approved by the suit team, all the hardware components were specified and procured. The systems were then packaged, fabricated, and thoroughly tested. The next step was to certify the equipment for manned used, which included generating a Hazard Analysis and giving a presentation to the Test Readiness Review Board. Both of these test support systems will perform critical roles in the development of next‐generation space suits. They will used on a regular basis to test the NASA's new Z‐2 Space Suit. The Space Suit Cooling System is now the primary cooling system for all advanced suit tests.

Watters, Jeffrey A.↗

NASA NTRS2004

NASA Processes and Requirements for Conducting Human-in-the-Loop Closed Chamber Tests

NASA has specific processes and requirements that must be followed for tests involving human subjects to be conducted in a safe and effective manner. There are five distinct phases of test operations. Phase one, the test request phase, consists of those activities related to initiating, processing, reviewing, and evaluating the test request. Phase two, the test preparation phase consists of those activities related to planning, coordinating, documenting, and building up the test. Phase three, the test readiness phase consists of those activities related to verifying and reviewing the planned test operations. Phase four, the test activity phase, consists of all pretest operations, functional checkouts, emergency drills, and test operations. Phase five, the post test activity phase, consists of those activities performed once the test is completed, including briefings, documentation of anomalies, data reduction and archiving, and reporting. Project management processes must be followed for facility modifications and major test buildup, which include six phases: initiation and assessment, requirements evaluation, preliminary design, detailed design, use readiness review (URR) and acceptance. Compliance with requirements for safety and quality assurance are documented throughout the test buildup and test operation processes. Tests involving human subjects must be reviewed by the applicable Institutional Review Board (IRB).

Barta, Daniel J.↗

NASA NTRS2004

CFM Analysis, Documentation, and Planning Support

The Multipurpose Hydrogen Test Bed (MHTB) Test Readiness Review (TRR), in preparation for upcoming thermodynamic vent system testing with LN2 (an LO2 simulant), was conducted on Aug 10 with no significant concerns or open action items. The 21 day test series, designed to evaluate the spray bar mixer/vent system concept suitability for zero-g operation began on August 19. The testing is progressing very well and results indicate that the Moog latching valve is more effective than the Castor solenoid valve in reducing pressure during the vent/mixing cycles. Testing with self-pressurization is expected to be completed on September 3 and testing with helium pressurization will be initiated on September 4 or 5. Additional activities during first half of August included coordination of Notification of Intent (NOI) to propose letters involving CFM in response to the HR&T BAA for Extramural Proposals.

Hastings, Leon J.↗

NASA NTRSDate not supplied

Effect of Carbon Dioxide Exposure on Physical and Cognitive Performance in a Simulated Spaceflight Contingency Scenario

Introduction: Carbon dioxide (CO2) produced by astronauts inside space suits can accumulate to levels that affect health and performance. The human health and performance risks associated with different levels of CO2 exposure in the flight environment remain an area of debate. The purpose of this study is to characterize the limit of acceptable performance (cognitive and physical) decrements and symptom severity for mission operations when subjected to elevated inspired CO2 levels in the spacesuit during contingency EVA scenarios. Methods: This study will create a simulation of a 1-hour contingency EVA walk back to the habitat, incorporating a passive treadmill and a fully immersive virtual reality (VR) simulation of a lunar EVA. Subjects will be asked to walk on a treadmill while breathing partial pressures of CO2 of 0, 5, 10, 15, 20, 25, 30mmHg for 1 hour at a time. Cognitive performance will be quantified using validated cognitive tests and measures of functional task performance embedded within the VR environment. Test subject symptoms and self-assessment of performance will be evaluated via survey. Results: This study currently has approval from NASA’s Institutional Review Board and has completed the Test Readiness Review process. Next steps for this research study include test subject recruitment, data collection, and analysis. Data collection is planned for calendar year 2022 and 2023. Discussion: This study will provide valuable information regarding how various partial pressures of CO2 exposure impact acute health, as well as cognitive and physical performance during simulated lunar EVA. This information will be vital in the assessment of overall risk associated with current hardware (vehicle and suit) design for upcoming exploration missions. It will also be invaluable for informing future standards and requirements.

carbon dioxide↗

NASA NTRSDate not supplied

Effect of Carbon Dioxide Exposure on Physical and Cognitive Performance in A Simulated Spaceflight Contingency Scenario

INTRODUCTION: Carbon dioxide (CO2) produced by astronauts inside space suits can accumulate to levels that may affect health and performance. The human health and performance risks associated with different levels of CO2 exposure in the flight environment remain an area of debate. The purpose of this study is to characterize the limit of acceptable performance (cognitive and physical) decrements and symptom severity for mission operations when subjected to elevated inspired CO2 levels in simulated contingency lunar extravehicular activity (EVA) scenarios. METHODS: This study will create a simulation of a 1-hour, ~2km contingency EVA walk back to a habitat, incorporating a passive treadmill and a fully immersive virtual reality (VR) simulation of a lunar EVA environment. Subjects will be asked to walk on a treadmill while breathing partial pressures of CO2 of 0, 5, 10, 15, 20, 25, 30mmHg for 1 hour at a time. Cognitive performance will be quantified using validated cognitive tests and measures of functional task performance embedded within the VR environment. Test subject symptoms and self-assessment of performance will be evaluated via survey. RESULTS: This study currently has approval from NASA’s Institutional Review Board and has completed the Test Readiness Review process. Next steps for this research study include test subject recruitment, data collection, and analysis. Data collection is planned for calendar year 2023 and 2024. DISCUSSION: This study will provide valuable information regarding how various partial pressures of CO2 exposure impact acute health, as well as cognitive and physical performance during simulated contingency lunar EVA. This information will enable assessment of health and performance risk associated with spacesuit systems and operations concepts for future exploration missions as well as informing definition of future standards and requirements.

D. M. Nusbaum↗

NASA NTRSDate not supplied

Effect of Carbon Dioxide Exposure on Physical and Cognitive Performance in A Simulated Spaceflight Contingency Scenario

carbon dioxide↗

NASA NTRS1977

Tracking system performance tests in the MDS era

Tracking system performance tests as developed to support DSN Mark III Data Subsystem implementation project and prepass readiness tests are described. The system test design, the rationale chosen for implementation, and the inevitable compromises imposed by schedule constraints and reserves are discussed.

Buckles, B. J.↗

NASA NTRSDate not supplied

Ground Testing of an Oxygen Concentrator in a Simulated International Space Station (ISS) Cabin Environment

The method for supplying medical oxygen to respiratorily-compromised astronauts on the International Space Station (ISS) and in future Orion missions consists of drawing oxygen from high pressure oxygen tanks. An Oxygen Concentrator Module (OCM) is a device that pulls in ambient air and separates out the nitrogen, resulting in a high concentration oxygen source. This technology has the potential to eliminate resupply and oxygen-enrichment issues associated with using high pressure oxygen tanks and become an alternative technology to support medical oxygen operations for future exploration missions. In this study, we test the long-term performance of a Commercial Off-the-Shelf (COTS) OCM in a simulated ISS cabin environment. Humidified air, carbon dioxide, and fifteen representative trace contaminants are continuously injected through a enclosed test chamber where the OCM is challenged. This study included the first successful demonstration of the Trace Gas Injection System (TGIS), which reliably and continuously produced ISS levels of trace contaminants, carbon dioxide, and humidity in an enclosed environment. The TGIS is a new and unique ground capability with significant implications for Test Readiness Level (TRL) advancement of COTS items and Government Furnished Equipment (GFE). This study demonstrated that the tested OCM reliably delivers enriched oxygen mostly at desired performance specifications. This study also demonstrated that the OCM does not inadvertently concentrate trace gases in its oxygen product stream, as detectable concentrations of trace contaminants in the oxygen product stream were at all times below the simulated ISS levels.

medical oxygen↗

NASA NTRSDate not supplied

Ground Testing of an Oxygen Concentrator in a Simulated International Space Station (ISS) Cabin Environment

The method for supplying medical oxygen to respiratorily-compromised astronauts on the International Space Station (ISS) and in future Orion missions consists of drawing oxygen from high pressure oxygen tanks. An Oxygen Concentrator Module (OCM) is a device that pulls in ambient air and separates out the nitrogen, resulting in a high concentration oxygen source. This technology has the potential to eliminate resupply and oxygen-enrichment issues associated with using high pressure oxygen tanks and become an alternative technology to support medical oxygen operations for future exploration missions. In this study, we test the long-term performance of a Commercial Off-the-Shelf (COTS) OCM in a simulated ISS cabin environment. Humidified air, carbon dioxide, and fifteen representative trace contaminants are continuously injected through an enclosed test chamber where the OCM is challenged. This study included the first successful demonstration of the Trace Gas Injection System (TGIS), which reliably and continuously produced ISS levels of trace contaminants, carbon dioxide, and humidity in an enclosed environment. The TGIS is a new and unique ground capability with significant implications for Test Readiness Level (TRL) advancement of COTS items and Government Furnished Equipment (GFE). This study demonstrated that the tested OCM reliably delivers enriched oxygen mostly at desired performance specifications. This study also demonstrated that the OCM does not inadvertently concentrate trace gases in its oxygen product stream, as detectable concentrations of trace contaminants in the oxygen product stream were at all times below the simulated ISS levels.

medical oxygen↗

NASA NTRS2015

CPAS Preflight Drop Test Analysis Process

Throughout the Capsule Parachute Assembly System (CPAS) drop test program, the CPAS Analysis Team has developed a simulation and analysis process to support drop test planning and execution. This process includes multiple phases focused on developing test simulations and communicating results to all groups involved in the drop test. CPAS Engineering Development Unit (EDU) series drop test planning begins with the development of a basic operational concept for each test. Trajectory simulation tools include the Flight Analysis and Simulation Tool (FAST) for single bodies, and the Automatic Dynamic Analysis of Mechanical Systems (ADAMS) simulation for the mated vehicle. Results are communicated to the team at the Test Configuration Review (TCR) and Test Readiness Review (TRR), as well as at Analysis Integrated Product Team (IPT) meetings in earlier and intermediate phases of the pre-test planning. The ability to plan and communicate efficiently with rapidly changing objectives and tight schedule constraints is a necessity for safe and successful drop tests.

Englert, Megan E.↗

NASA NTRS1974

Simulator verification techniques study. Integrated simulator self test system concepts

Software and hardware requirements for implementing hardware self tests are presented in support of the development of training and procedures development simulators for the space shuttle program. Self test techniques for simulation hardware and the validation of simulation performance are stipulated. The requirements of an integrated simulator self system are analyzed. Readiness tests, fault isolation tests, and incipient fault detection tests are covered.

Montoya, G.↗

NASA NTRS2008

Initial Assessment of the Ares I-X Launch Vehicle Upper Stage to Vibroacoustic Flight Environments

The Ares I launch vehicle will be NASA s first new launch vehicle since 1981. Currently in design, it will replace the Space Shuttle in taking astronauts to the International Space Station, and will eventually play a major role in humankind s return to the Moon and eventually to Mars. Prior to any manned flight of this vehicle, unmanned test readiness flights will be flown. The first of these readiness flights, named Ares I-X, is scheduled to be launched in April 2009. The NASA Glenn Research Center is responsible for the design, manufacture, test and analysis of the Ares I-X upper stage simulator (USS) element. As part of the design effort, the structural dynamic response of the Ares I-X launch vehicle to its vibroacoustic flight environments must be analyzed. The launch vehicle will be exposed to extremely high acoustic pressures during its lift-off and aerodynamic stages of flight. This in turn will cause high levels of random vibration on the vehicle's outer surface that will be transmitted to its interior. Critical flight equipment, such as its avionics and flight guidance components are susceptible to damage from this excitation. This study addresses the modelling, analysis and predictions from examining the structural dynamic response of the Ares I-X upper stage to its vibroacoustic excitations. A statistical energy analysis (SEA) model was used to predict the high frequency response of the vehicle at locations of interest. Key to this study was the definition of the excitation fields corresponding to lift off acoustics and the unsteady aerodynamic pressure fluctuations during flight. The predicted results will be used by the Ares I-X Project to verify the flight qualification status of the Ares I-X upper stage components.

Larko, Jeffrey M.↗

NASA NTRS2022

Moon to Mars (M2M) Habitation Considerations: A Snap Shot As of January 2022

The following NASA Technical Memorandum (TM) is intended to provide a snapshot in time of NASA’s current considerations (ground rules and assumptions, functional allocations, logistics) for habitation systems for the lunar surface (non-roving) and Mars transits. As NASA continues to refine the reference designs to meet the needs of an evolving architecture, it is expected that this information will also be updated as a result. Where appropriate, relevant publicly released documents will be referenced to provide further detail. NASA’s human lunar exploration plan under the Artemis program calls for achieving the goal of sending the first woman and first person of color to the surface of the Moon in the mid- 2020s and working toward sustainable exploration by the end of the decade. Working with both commercial and international partners, NASA will establish a permanent human presence on the Moon to uncover new scientific discoveries and lay the foundation for private companies to build a lunar economy. Longer duration missions on the lunar surface and in lunar orbit will also serve as a test bed for technologies to support future Mars exploration campaigns. The agency will use what we learn on the Moon to prepare for humanity's next giant leap – sending astronauts to Mars. NASA intends to establish a sustained lunar presence with the development of the Artemis Base Camp to prove technologies and capabilities that will one day enable humans to live and work on Mars, beginning with core elements including the Lunar Terrain Vehicle (LTV), the Pressurized Rover (PR), the lunar Surface Habitat (SH), power systems, and in-situ resource utilization (ISRU) systems. For in space operations and eventual transport of humans to Mars, NASA will utilize a Mars Transit Habitat (TH). Following deployment, the TH will complete a series of longer duration missions and shakedown testing while docked at Gateway, leveraging Gateway’s habitation redundancy for safety measures. Proposed Gateway-TH missions will far exceed the longest duration cislunar human missions to date. They will be the first operational readiness tests of our long-duration deep space systems, and of the split crew (two crew on the surface, two crew in space) operations that are vital to the approach for the first human Mars mission. Both the SH and TH are major architectural elements of NASA’s Moon to Mars (M2M) approach, each with very different concepts of operation. The SH is intended for use on the lunar surface as a home for astronauts, surface operations base, science facility, hub for communications, extravehicular activity (EVA) equipment repair site, waste processing facility, and supply hub. It serves as an enabler for a sustained surface presence and preparation for partial gravity operations during Mars missions. The SH will be designed to be self-sufficient for operations on the lunar surface. The SH will independently provide several functions, including its own power generation, energy storage capability, sleep quarters, hygiene areas, work areas, and dining areas. It will be capable of communicating with surface assets, orbital assets, and directly with Earth ground stations. It is planned to operate with two crew in the habitat for ~28- day stays with crew swap-outs in which the PR crew of two trades places with the habitat crew. During the swap-out, the habitat will nominally support four crew for a short period of time. For contingency scenarios, the habitat must also be capable of supporting four crew for up to 7 days. The TH will be designed to be capable of up to ~1,200-day Mars missions with the ability to carry all food and supplies needed to support a crew of four for this duration. An assumed Mars mission profile for the TH is to carry crew and supplies for ~850-day roundtrips between Earth and Mars orbit that allows 30-day stays on the Martian surface. To test the systems for this long journey, the TH will be used to extend the duration of missions at Gateway, enabling the orbiting outpost to be used as a Mars analog. These analog missions will be accomplished by attaching the TH to Gateway and conducting lunar surface operations from the TH. The TH may also need to perform free-flying shakedown missions to test out all systems prior to leaving for Mars. The habitat provides many critical functions including: a contingency airlock, crew quarters, galley, hygiene areas, safe haven capability, and science equipment. It can receive docked items from either axial end or on a radial port.

Habitat↗

NASA NTRS2023

Development of an Ultra High-Pressure Metals Promoted Combustion in Oxygen Test Apparatus

Materials flammability data is needed at pressures higher than ever tested before (greater than 10,000 psi). WSTF has designed and is currently building a metals flammability apparatus that can test metals up to 30,000 psi. Solid progress was achieved on the chamber in terms of system build up and fulfilling requirements to perform a NASA Test Readiness Review. Understanding metals flammability data at extreme pressure opens the doors for higher pressure and higher performance oxygen systems. Proposed systems include more reliable/higher performance propulsion systems and more reliable/lighter Environmental Control Life Support Systems (ECLSS). The test system needed for this testing required significant research and development to select a pressurization method and eliminate contact with potentially flammable materials back to the chamber. No additional promoted combustion data was collected in FY21. This International Research & Development (IRAD) proposal was critical to getting the system very close to operational status. This capability is critical to collect forward leaning material flammability data for future spacecraft and ground systems. Forward work has been identified and funding is being sought outside of the Center Innovation Fund (CIF) process for late FY23/FY24.

promoted combustion↗

NASA NTRS1994

A new presentation of complex voltage data for Goldstone radar astronomy

A presentation method similar to a vector field display or a data-based grid has been used to visualize complex voltage test data taken over multiple subchannels. Unlike simple plots of all data points on the complex plane, the position of the data in the time series is part of the presentation, providing additional information to aid in fault isolation during readiness testing. The 'phase-magnitude' presentation, as it has come to be called, was designed for the demands of real-time data acquisition and processing with remote monitoring over low bandwidth communication links.

Howard, S. D.↗

NASA NTRS1986

Design, construction, activation, and operation of a high intensity acoustic test chamber

The design philosophy, construction, integration, and activation of the high intensity acoustic test chamber for production acceptance testing of satellites are discussed. The 32,000 cubic-foot acoustic test cell consists of a steel reinforced concrete chamber with six electropneumatic noise generators. One of the innovative features of the chamber is a unique quarter horn assembly that acoustically couples the noise generators to the chamber. Design concepts, model testing, and evaluation results are presented. Considerations such as nitrogen versus compressed air source, digital closed loop spectrum control versus manual equalizers, and microprocessor based interlock systems are included. Construction difficulties, anomalies encountered, and their resolution are also discussed. Results of the readiness testing are highlighted.

Kamel, L. T.↗

NASA NTRSDate not supplied

Capability Gaps Assessment and Identification of Critical Technology Elements for Mars Transit Habitat

The Habitation Systems Development Office (HP40) at NASA Marshall Space Flight Center supports systems engineering, integration, and project management for next generation space habitats. For in space operations and eventual transport of humans to Mars, NASA will rely on a Mars Transit Habitat (TH). The TH will be designed for an up to 1,200-day Mars mission and will carry all food and supplies needed to support four crew for this duration. In the current concept of operations, Mars TH transfers to near rectilinear halo orbit (NRHO) following launch and docks at Gateway as a visiting vehicle. While there, the TH will complete system shakedown testing and a series of analog missions which will grow from 3 to 6+ months in duration TH also augments Gateway’s habitation capabilities beyond 60-days. Proposed Gateway-TH missions will far exceed the longest duration cislunar human missions to date. These shakedown missions will also be the first operational readiness tests of Mars TH’s long-duration deep space systems, and of the split crew (two crew on the surface, two crew in space) operations that are vital to the approach for the first human Mars mission. Once shakedown missions are complete, Mars TH departs Gateway to aggregate with the Mars propulsion system in NRHO before onboarding the crew and final supplies in Earth orbit via a co-manifested Orion-logistics module. Orion and the LM return to Earth prior to the now aggregated Deep Space Transport vehicle’s journey to Mars. Development of the Mars TH requires significant technology development and maturation. Each year the agency performs a capability gaps assessment, where gaps developed by subject matter experts (SMEs) in various engineering/science disciplines are linked to architectural elements in formulation and prioritized. A gap captures the difference between the current state-of-the-art and the maturity of the capability that is needed to enable or enhance a mission as it is currently envisioned in the government reference architecture. HP40 conducted a gap analysis for Mars TH which will be summarized in this poster. Gaps classified as enabling (which means the mission cannot achieve success without gap closure) were subsequently used to identify critical technology elements (CTEs) for Mars TH. This identification of CTEs was also informed by an examination of the product breakdown structure for Mars TH and focused conversations with SMEs in specific technology areas. CTEs identified for Mars TH to date include the following (note this is not a comprehensive list – CTEs listed represent those in MSFC’s capability areas): inflatable softgoods for habitation; enhanced CO2 recovery; life support systems with greater levels of reliability and maintainability; autonomous guidance, navigation, command and control; and radiators for the Mars TH application. The habitation systems development team is currently delving deeper into each CTE to assess technology approaches being pursued, their maturity, and the degree of difficulty in maturation to meet projected Mars TH timelines. This poster will summarize work to date on the identification of enabling capability gaps linked to Mars TH and provide insight into the associated CTEs and technology maturation efforts.

technology development↗

NASA NTRS1997

An Exposure Prevention Plan for an Anhydrous Ammonia Handling System

In July of 1996, the Industrial Hygiene Team of the Environmental Management Office at NASA Lewis Research Center was contacted by the Space Station Program Office to conduct ammonia awareness training for a team of engineers and technicians. The team was tasked with assembling and operating an ammonia handling system for testing of a photovoltaic radiator at the NASA Plum Brook Station Space Power Facility. The ammonia handling system supports a radiator designed to radiate excess heat from a photovoltaic array module used to provide power to the International Space Station. The system would consist of a hazardous materials trailer equipped with an anhydrous ammonia tank, heater, accumulator, chiller, and flow bench. Meetings were held with representatives from the Space Station Program Office, the engineers and Plum Brook safety personnel. Guidance was also provided by representatives from Kennedy Space Center. Determinations were made concerning the locations and types of potential exposures and a plan was developed which included training, personal protective equipment, engineering controls and emergency response. Various organizations including the Plum Brook Safety Committee, the Lewis Environmental Management Office, the Test Readiness Review Board and the Program Office all had requirements that had to be met in order to satisfy themselves that all personnel involved in the operation of the system would be safe. What resulted was a comprehensive plan that provided more than adequate safety measures and succeeded in protecting all personnel from the hazards of the ammonia system. Testing of the photovoltaic radiator was successful and although ammonia leaks were detected and maintenance of the system was ongoing, no one was injured. It was felt that the training and controls in place allowed for a comfort level that did not interfere with the operations.

Cathy L Padolewski↗