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All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Lessons We Learned Designing and Building the Chandra Telescope

2014 marks the crystal (15th) anniversary of the launch of the Chandra X‐ray Observatory. This paper offers some of the major lessons learned by some of the key members of the Chandra Telescope team. We offer some of the lessons gleaned from our experiences developing, designing, building and testing the telescope and its subsystems, with 15 years of hindsight. Among the topics to be discussed are the early developmental tests, known as VETA‐I and VETA‐II, requirements derivation, the impact of late requirements and reflection on the conservatism in the design process.

Arenberg, Jonathan↗
NASA NTRS2011

MicroShell Minimalist Shell for Xilinx Microprocessors

MicroShell is a lightweight shell environment for engineers and software developers working with embedded microprocessors in Xilinx FPGAs. (MicroShell has also been successfully ported to run on ARM Cortex-M1 microprocessors in Actel ProASIC3 FPGAs, but without project-integration support.) Micro Shell decreases the time spent performing initial tests of field-programmable gate array (FPGA) designs, simplifies running customizable one-time-only experiments, and provides a familiar-feeling command-line interface. The program comes with a collection of useful functions and enables the designer to add an unlimited number of custom commands, which are callable from the command-line. The commands are parameterizable (using the C-based command-line parameter idiom), so the designer can use one function to exercise hardware with different values. Also, since many hardware peripherals instantiated in FPGAs have reasonably simple register-mapped I/O interfaces, the engineer can edit and view hardware parameter settings at any time without stopping the processor. MicroShell comes with a set of support scripts that interface seamlessly with Xilinx's EDK tool. Adding an instance of MicroShell to a project is as simple as marking a check box in a library configuration dialog box and specifying a software project directory. The support scripts then examine the hardware design, build design-specific functions, conditionally include processor-specific functions, and complete the compilation process. For code-size constrained designs, most of the stock functionality can be excluded from the compiled library. When all of the configurable options are removed from the binary, MicroShell has an unoptimized memory footprint of about 4.8 kB and a size-optimized footprint of about 2.3 kB. Since MicroShell allows unfettered access to all processor-accessible memory locations, it is possible to perform live patching on a running system. This can be useful, for instance, if a bug is discovered in a routine but the system cannot be rebooted: Shell allows a skilled operator to directly edit the binary executable in memory. With some forethought, MicroShell code can be located in a different memory location from custom code, permitting the custom functionality to be overwritten at any time without stopping the controlling shell.

Werne, Thomas A.↗
NASA NTRSDate not supplied

4-Bed CO2 Scrubber – From Design to Build

Four-bed technology is an International Space Station (ISS) mainstay for metabolic Carbon Dioxide (CO2) removal and crew life support. The current generation is known as the Carbon Dioxide Removal Assembly (CDRA) and has a long history of unplanned maintenance as well as obsolete core components. The 4-bed CO2 Scrubber was commissioned to operate with no unplanned maintenance for 3 years while removing 4 crew-equivalents of CO2 at a target inlet concentration of 2 torr CO2. This work goes into detail of the various design aspects that have been undertaken to ensure a successful project design and successful build leading to an upcoming flight. This work will discuss the compromises caught both early and late in the design cycle and the adaptations in response. Finally, the expected performance of the system once launched will be discussed based on summaries of data from the testbed.

Carbon Dioxide↗
NASA NTRS2011

Design and Build of Reactor Simulator for Fission Surface Power Technology Demonstrator Unit

The Nuclear Systems Team at NASA Marshall Space Flight Center (MSFC) focuses on technology development for state of the art capability in non-nuclear testing of nuclear system and Space Nuclear Power for fission reactor systems for lunar and Mars surface power generation as well as radioisotope power systems for both spacecraft and surface applications. Currently being designed and developed is a reactor simulator (RxSim) for incorporation into the Technology Demonstrator Unit (TDU) for the Fission Surface Power System (FSPS) Program, which is supported by multiple national laboratories and NASA centers. The ultimate purpose of the RxSim is to provide heated NaK to a pair of Stirling engines in the TDU. The RxSim includes many different systems, components, and instrumentation that have been developed at MSFC while working with pumped NaK systems and in partnership with the national laboratories and NASA centers. The main components of the RxSim are a core, a pump, a heat exchanger (to mimic the thermal load of the Stirling engines), and a flow meter for tests at MSFC. When tested at NASA Glenn Research Center (GRC) the heat exchanger will be replaced with a Stirling power conversion engine. Additional components include storage reservoirs, expansion volumes, overflow catch tanks, safety and support hardware, instrumentation (temperature, pressure, flow) for data collection, and power supplies. This paper will discuss the design and current build status of the RxSim for delivery to GRC in early 2012.

Godfroy, Thomas↗
NASA NTRS1995

Spacecraft Cabin Air Quality Control and Its Application to Tight Buildings

Air quality is an important consideration not only for the external environment, but also for the indoor environment. Most people spend a majority of their lives indoors and the air that they breathe is important to their physical and emotional well being. Since most modern building designs have focused on energy efficiency, less fresh air is brought from the outside. As a result, pollutants from building materials, furniture, cleaning, and cooking have no place to go. To make matters worse, most ventilation systems do not include any means for removing pollutants from the recycled air. Unfortunately, pollution at even a small level can result in eye, throat, and lung irritation in addition to chronic headaches, nausea, and fatigue. A spacecraft cabin, which represents the worst case in tight building design, requires special consideration of air quality since any effects pollutants may have on a crewmember can potentially place a mission or other crewmembers at risk. A detailed approach has been developed by the National Aeronautics and Space Administration (NASA) to minimize cabin atmosphere pollution and provide the crew with an environment which is as free of pollutants as possible. This approach is a combination of passive and active contamination control concepts involving the evaluation and selection of materials to be used onboard the spacecraft, the establishment of air quality standards to ensure crew health, and the use of active control means onboard the spacecraft to further ensure an acceptable atmosphere. This approach has allowed NASA to prevent illness by providing crewmembers with a cabin atmosphere which contains pollutant concentrations up to 100 times lower than those specified for terrestrial indoor environments. Standard building construction, however, does not take into account the potentially harmful effects of materials used in the construction process on the health of future occupants and relies primarily on remedial rather than preventive techniques when addressing contamination. This approach results in a building that theoretically has low operating costs, but may actually have high costs associated with lost work days, increased medical claims, decreased productivity, and problem remediation. A similar approach to NASA's may be adopted by the building construction community which can tap the extensive database of material offgassing properties that has been collected to support the space program. Many materials used by NASA are commercially available and are frequently used in building construction. In addition, computer models which have been developed for assessing various methods of active contamination control can be applied to building ventilation system design and the analysis of their economics. Through using NASA' s experience, the expense associated with the current remedial approach can be avoided.

Perry, J. L.↗
NASA NTRS1988

Design guide: Designing and building high voltage power supplies, volume 1

This report contains an accumulation of publications and analyses aimed at developing guidelines for improving both high voltage and low voltage power supplies for the U.S. Air Force systems command. It is the intent of the report to supply good design and manufacturing techniques for the packaging and the building of high quality, reliable, long-life power supplies. These data are based on the wealth of engineering practices established by design and manufacturing engineers.

William G Dunbar↗
NASA NTRS1988

Design guide: Designing and building high voltage power supplies, volume 2

This report contains an accumulation of publications and analyses aimed at developing guidelines for improving both high voltage and low voltage power supplies for the U.S. Air Force systems command. It is the intent of the report to supply good design and manufacturing techniques for the packaging and the building of high quality, reliable, long-life power supplies. These data are based on the wealth of engineering practices established by design and manufacturing engineers. The contents are: Fundamentals of Insulation: Gases, Liquid Dielectrics, Solid Insulation; Environment: Pressure, Particulates, Environmental Interactions with Space Power Systems, Surface Charging, System Design Criteria; Configuration and Design Data: Designs, Transients, Grounding and Bonding, Thermal Control; Materials and Processes: Insulation, Processes, Process Variables; Manufacturing: Yield, Government and Industrial Survey, Analysis, Problem Areas and Suggested Solutions, Designs That Have Worked in High Voltage Equipment, Manufacturing Summary; and Tests: Performance, Insulation Tests, Materials Testing, Component and Equipment Tests, Performance Testing, Facility and Environment, Accelerated Life Test; Maintenance and Repair: Maintenance, Test Sets, Pilots and Crewmen, Air Logistic Centers, Design Problem Recommendations.

W G Dunbar↗
NASA NTRS1982

NECAP 4.1: NASA's Energy-Cost Analysis Program input manual

The computer program NECAP (NASA's Energy Cost Analysis Program) is described. The program is a versatile building design and energy analysis tool which has embodied within it state of the art techniques for performing thermal load calculations and energy use predictions. With the program, comparisons of building designs and operational alternatives for new or existing buildings can be made. The major feature of the program is the response factor technique for calculating the heat transfer through the building surfaces which accounts for the building's mass. The program expands the response factor technique into a space response factor to account for internal building temperature swings; this is extremely important in determining true building loads and energy consumption when internal temperatures are allowed to swing.

Jensen, R. N.↗
NASA NTRS1992

Industry survey of space system cost benefits from New Ways Of Doing Business

The cost of designing, building and operating space system hardware has always been expensive. Small quantities of specialty parts escalate engineering design, production and operations cost. Funding cutbacks and shrinking revenues dictate aggressive cost saving programs. NASA's highest priority is providing economical transportation to and from space. Over the past three decades NASA has seen technological advances that provide grater efficiencies in designing, building, and operating of space system hardware. As future programs such as NLS, LUTE and SEI begin, these greater efficiencies and cost savings should be reflected in the cost models. There are several New Ways Of Doing Business (NWODB) which, when fully implemented will reduce space system costs. These philosophies and/or culture changes are integrated in five areas: (1) More Extensive Pre-Phase C/D & E, (2) Multi Year Funding Stability, (3) Improved Quality, Management and Procurement Processes, (4) Advanced Design Methods, and (5) Advanced Production Methods. Following is an overview of NWODB and the Cost Quantification Analysis results using an industry survey, one of the four quantification techniques used in the study. The NWODB Cost Quantification Analysis is a study performed at Marshall Space Flight Center by the Engineering Cost Group, Applied Research Incorporated and Pittsburg State University. This study took place over a period of four months in mid 1992. The purpose of the study was to identify potential NWODB which could lead to improved cost effectiveness within NASA and to quantify potential cost benefits that might accrue if these NWODB were implemented.

Rosmait, Russell L.↗
NASA NTRS2016

Designing and Building a Crew-Centric Mobile Scheduling and Planning Tool for Exploring Crew Autonomy Concepts Onboard the International Space Station

During 2015, as part of our ongoing research on crew autonomy, our team adapted and extended the plan viewing tool, Playbook, into a mobile tool for exploring crew autonomy onboard the International Space Station (ISS). This work enables crewmembers to intuitively re-plan and schedule on their own with limited input from mission control. Designed for ease of use, re-planning is composed of simple drag and drop interactions and learning the tool requires little to no training. Playbook was successfully uplinked onto ISS as a technology demonstration and completed its onboard ground and crew checkouts in August and September 2015, respectively. We will discuss and describe how Playbook was able to integrate with actual ISS operational plans and operational procedures without disrupting real mission operations. This work will also outline the design and technical constraints required to build a collaborative tool that allows multiple users to simultaneously self-schedule and synchronize during communication dropouts in the restricted networking and computing environment onboard ISS. Finally, we will explore the aspects of crew autonomy that this technology enables as well as discuss our next steps and possible extensions.

ISS↗
NASA NTRSDate not supplied

Lessons Learned From Designing and Building Low Organic Outgassing Cleanrooms for NASA OSIRIS-REx and Hayabusa2 Curation Facility

NASA Johnson Space Center Astromaterials Acquisition and Curation Office completed construction and commissioning of the OSIRIS-REx and Hayabusa2 cleanroom laboratory suites along with new precision cleaning and advanced curation laboratories consisting of ISO Class 5, 6, and 7 cleanrooms. The new curation facilities are designed for initial receiving, basic characterization, curation processing, and preliminary examination of carbonaceous asteroidal material. The facilities are also designed to enable long-term pristine sample storage to preserve the scientific integrity of each sample to enable future research by the international science community. The scientific study of organics is critical for both missions. The OSIRIS-REx mission instituted a stringent contamination control plan for low organics. Given these mission requirements and long-term storage preservation requirements, cleanroom construction materials were carefully selected to not hinder the scientific search for amino acids and the study of organics in the samples. Cleanroom candidate construction materials were researched for the HVAC system, floors, walls, ceiling, and plenum areas. The team chose several candidate materials that were further tested for their specific outgassing characteristics using ASTM E-595 per ASTM E-2312. The information gained provided the foundation for the final design selection of the cleanroom materials. While material selection is important before and during the facility design phase, the construction phase is where these choices are implemented by the prime construction contractor through final product and material submittals. These submittals are the last check point and changes are often submitted due to engineering/construction conflicts, especially when renovating an existing building. Any new material or equipment/product change must be identified and scrutinized for low particulate shedding and outgassing properties. In some cases, quick testing of new material is required, and compromises must be made in real-time. Careful selection and implementation of cleanroom materials significantly reduced organic and inorganic contamination beyond normal cleanroom baselines.

astromaterials curation↗
NASA NTRSDate not supplied

Lessons Learned From Designing and Building Low Organic Outgassing Cleanrooms for NASA OSIRIS-REx and Hayabusa2 Curation Facility

NASA Johnson Space Center Astromaterials Acquisition and Curation Office completed construction and commissioning of the OSIRIS-REx and Hayabusa2 cleanroom laboratory suites along with new precision cleaning and advanced curation laboratories consisting of ISO Class 5, 6, and 7 cleanrooms. The new curation facilities are designed for initial receiving, basic characterization, curation processing, and preliminary examination of carbonaceous asteroidal material. The facilities are also designed to enable long-term pristine sample storage to preserve the scientific integrity of each sample to enable future research by the international science community. The scientific study of organics is critical for both missions. The OSIRIS-REx mission instituted a stringent contamination control plan for low organics. Given these mission requirements and long-term storage preservation requirements, cleanroom construction materials were carefully selected to not hinder the scientific search for amino acids and the study of organics in the samples. Cleanroom candidate construction materials were researched for the HVAC system, floors, walls, ceiling, and plenum areas. The team chose several candidate materials that were further tested for their specific outgassing characteristics using ASTM E-595 per ASTM E-2312. The information gained provided the foundation for the final design selection of the cleanroom materials. While material selection is important before and during the facility design phase, the construction phase is where these choices are implemented by the prime construction contractor through final product and material submittals. These submittals are the last check point and changes are often submitted due to engineering/construction conflicts, especially when renovating an existing building. Any new material or equipment/product change must be identified and scrutinized for low particulate shedding and outgassing properties. In some cases, quick testing of new material is required, and compromises must be made in real-time. Careful selection and implementation of cleanroom materials significantly reduced organic and inorganic contamination beyond normal cleanroom baselines.

astromaterials curation↗
NASA NTRS2000

Fixed-Order Mixed Norm Designs for Building Vibration Control

This study investigates the use of H2, mu-synthesis, and mixed H2/mu methods to construct full order controllers and optimized controllers of fixed dimensions. The benchmark problem definition is first extended to include uncertainty within the controller bandwidth in the form of parametric uncertainty representative of uncertainty in the natural frequencies of the design model. The sensitivity of H2 design to unmodeled dynamics and parametric uncertainty is evaluated for a range of controller levels of authority. Next, mu-synthesis methods are applied to design full order compensators that are robust to both unmodeled dynamics and to parametric uncertainty. Finally, a set of mixed H2/mu compensators are designed which are optimized for a fixed compensator dimension. These mixed norm designs recover the H2 design performance levels while providing the same levels of robust stability as the mu designs. It is shown that designing with the mixed norm approach permits higher levels of controller authority for which the H2 designs are destabilizing. The benchmark problem is that of an active tendon system. The controller designs are all based on the use of acceleration feedback.

Whorton, Mark S.↗
NASA NTRS2011

Generalized Software Architecture Applied to the Continuous Lunar Water Separation Process and the Lunar Greenhouse Amplifier

This innovation provides the user with autonomous on-screen monitoring, embedded computations, and tabulated output for two new processes. The software was originally written for the Continuous Lunar Water Separation Process (CLWSP), but was found to be general enough to be applicable to the Lunar Greenhouse Amplifier (LGA) as well, with minor alterations. The resultant program should have general applicability to many laboratory processes (see figure). The objective for these programs was to create a software application that would provide both autonomous monitoring and data storage, along with manual manipulation. The software also allows operators the ability to input experimental changes and comments in real time without modifying the code itself. Common process elements, such as thermocouples, pressure transducers, and relative humidity sensors, are easily incorporated into the program in various configurations, along with specialized devices such as photodiode sensors. The goal of the CLWSP research project is to design, build, and test a new method to continuously separate, capture, and quantify water from a gas stream. The application is any In-Situ Resource Utilization (ISRU) process that desires to extract or produce water from lunar or planetary regolith. The present work is aimed at circumventing current problems and ultimately producing a system capable of continuous operation at moderate temperatures that can be scaled over a large capacity range depending on the ISRU process. The goal of the LGA research project is to design, build, and test a new type of greenhouse that could be used on the moon or Mars. The LGA uses super greenhouse gases (SGGs) to absorb long-wavelength radiation, thus creating a highly efficient greenhouse at a future lunar or Mars outpost. Silica-based glass, although highly efficient at trapping heat, is heavy, fragile, and not suitable for space greenhouse applications. Plastics are much lighter and resilient, but are not efficient for absorbing longwavelength infrared radiation and therefore will lose more heat to the environment compared to glass. The LGA unit uses a transparent polymer antechamber that surrounds part of the greenhouse and encases the SGGs, thereby minimizing infrared losses through the plastic windows. With ambient temperatures at the lunar poles at 50 C, the LGA should provide a substantial enhancement to currently conceived lunar greenhouses. Positive results obtained from this project could lead to a future large-scale system capable of running autonomously on the Moon, Mars, and beyond. The software for both applications needs to run the entire units and all subprocesses; however, throughout testing, many variables and parameters need to be changed as more is learned about the system operation. The software provides the versatility to permit the software operation to change as the user requirements evolve.

Perusich, Stephen↗
NASA NTRS1995

Solar Eagle 2

During a 22-month period from February 1991 to December 1993, a dedicated group of students, faculty, and staff at California State University, Los Angeles completed a project to design, build, and race their second world class solar-powered electric vehicle, the Solar Eagle 2. This is the final report of that project. As a continuation of the momentum created by the success of the GM-sponsored Sunrayce USA in 1990, the U.S. Department of Energy (DOE) picked up the banner from General Motors as sponsors of Sunrayce 93. In February 1991, the DOE sent a request for proposals to all universities in North America inviting them to submit a proposal outlining how they would design, build, and test a solar-powered electric vehicle for a seven-day race from Arlington, Texas to Minneapolis, Minnesota, to be held in June 1993. Some 70 universities responded. At the end of a proposal evaluation process, 36 universities including CSLA were chosen to compete. This report documents the Solar Eagle 2 project--the approaches take, what was learned, and how our experience from the first Solar Eagle was incorporated into Solar Eagle 2. The intent is to provide a document that would assist those who may wish to take up the challenge to build Solar Eagle 3.

Roberto, Richard D.↗