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At least 397 records · Page 22

Orion Ground Test Article Water Impact Tests: Photogrammetric Evaluation of Impact Conditions

The Ground Test Article (GTA) is an early production version of the Orion Crew Module (CM). The structural design of the Orion CM is being developed based on LS-DYNA water landing simulations. As part of the process of confirming the accuracy of LS-DYNA water landing simulations, the GTA water impact test series was conducted at NASA Langley Research Center (LaRC) to gather data for comparison with simulations. The simulation of the GTA water impact tests requires the accurate determination of the impact conditions. To accomplish this, the GTA was outfitted with an array of photogrammetry targets. The photogrammetry system utilizes images from two cameras with a specialized tracking software to determine time histories for the 3-D coordinates of each target. The impact conditions can then be determined from the target location data.

Vassilakos, Gregory J.↗

On-Ground Calibration and Optical Alignment for the Orion Optical Navigation Camera

The Orion Multi-Purpose Crew Vehicle on-board Navigation System will utilize the Optical Navigation measurements of the Moon and Earth during cis-lunar operations. Misalignment or an un-calibrated optical navigation camera may cause large measurement residuals in any on-board attitude determination and navigation system. Therefore, a novel estimation technique to calibrate the internal camera parameters, and a high accuracy optical alignment procedure to estimate the external camera alignment are introduced in this paper. The intrinsic camera parameters such as the focal length, the principle point offsets, and the camera lens distortion parameters will be estimated and evaluated using images of star fields. This calibration estimation technique can be used either on-ground or in flight. The proposed technique in this paper is using the discrepancy between imaged star vectors attained from the OpNav camera, and the matched star vectors from the star catalog to determine the changes in internal camera parameters. This gave rise to the two basic types of calibration the attitude dependent and attitude independent methods. The former utilizes the errors in imaged and cataloged vectors themselves, and the latter using the discrepancy in angles between pairs of vectors from the camera and catalog. The alignment procedure is carried out using Theodolite autocollimator measurements taken off alignment cubes mounted on the Orion frame and also the measurements from the OpNav focal plane. It is assumed that the alignment cubes and OpNav camera are rigidly mounted to the frame so that flexing effects do not significantly alter the orientation of the cubes relative to the OpNav camera.

Samaan, Malak↗

Testing of the Orion Optical Navigation Image Processing Algorithms

The Optical Navigation System for Orion has been developed to ensure that the crew can return safely to Earth in case of a loss of communications. This presentation contains an overview of the image processing aspect of the Orion optical navigation system. The top level architecture is presented along with results of the testing of these image processing system.

Optical Navigation↗

Development and Qualification of the Primary Structure of the Orion European Service Module

This paper presents an overview of the development and qualification test campaign for the primary structure of the European Service Module of ORION, the NASA spacecraft which will serve the future human exploration missions to the Moon, Mars and beyond. Under an agreement between NASA and ESA, the ORION will be powered by a European Service Module (ESM), providing also water and oxygen for astronauts' life sustainability. The development and qualification of the European Service Module (ESM) is under ESA responsibility with Airbus Defense and Space as the prime contractor. Thales Alenia Space Italia is responsible for design development, manufacturing, assembly and qualification of the Structure subsystem. The European Service Module, installed onto the launch adapter, shall support the crew module with its adapter and a launch abort system. It shall sustain: - A combination of global and local launch loads during lift off and ascent phases, - On orbit loads induced by engine firing for orbital transfers and attitude control. The ESM structure is based on a core made of Composite Fiber Reinforced Polymer (CFRP) sandwich panels complemented by aluminum alloy platforms, longerons and secondary structures. A development campaign has been implemented in order to define and validate composite parts' strength allowable values for design: coupon tests at material level, test at component level up to breadboards tests performed on main structural components (composite to metallic joints, and at panels' discontinuities). An incremental approach as defined in [1] has been followed. A qualification static test campaign at primary structure assembly level has been implemented in order to validate the design against static stiffness and ultimate strength as well as to correlate the structural Finite Element Model (FEM) used for sizing and confirm the margins of safety. The tests have been performed successfully by Thales Alenia Space Italia (TAS-I) on two flight representative structural models (STA1, STA2), in Turin facilities (Italy) between August 2015 and March 2017, with engineering support of technical representatives from Airbus, ESA, NASA and LMCO. The main development and qualification test activities and associated results are presented and discussed in the paper

Structural Testing↗

Trajectory Reconstruction of Orion Ground Test Article Water Impact Tests

The Orion Crew Module is a component of NASA’s Multi-Purpose Crew Vehicle that will be used for future missions to low Earth orbit and beyond. Ten water impact tests of the Orion Ground Test Article (GTA) were conducted at the Hydro Impact Basin at NASA Langley Research Center in 2016 and were designed to provide data for the validation of the LS-DYNA model used to determine the Crew Module structural loads during ocean splashdown, and the determination of an acceptable Model Uncertainty Factor to apply to simulation results used to drive the design. Post-test data obtained from the onboard sensors were used to reconstruct the GTA trajectories both before and after water impact. Results from one vertical test and two swing tests are presented and compared to videos taken for each test.

Lugo, Rafael A.↗

Transient Heater Analysis for Orion Thermal Vacuum Testing

The Space Environments Complex (SEC) at NASA's Plum Brook Station is currently being prepared to perform thermal vacuum testing of the Orion spacecraft. This thermal vacuum, or T-VAC test will be run for a period of 60 days, which will be the longest such test ever conducted at SEC. The Orion Crew Module (CM) and Service Module (SM) will undergo T-VAC testing in SEC's Space Simulation Vacuum Chamber to ensure the functionality of these systems in a high vacuum environment at extremely cold temperatures. The T-VAC test setup in SEC was modeled and simulated in Thermal Desktop. The initial results from thermal analysis showed areas on the chamber floor to reach very low temperatures, which were below the minimum operating range of certain hardware located on or near the chamber floor. These hardware including elastomeric seals on the GN2 piping, bearing pads and O-rings are essential to both test and the operation of the SEC facility, and must be kept well above -20°F throughout the duration of the T-VAC test. Thus, further analysis was conducted to include the placement of patch heaters on the chamber floor in an effort to increase the temperature near colder areas on the floor. The results and findings from this analysis showed that using these heaters will result in a favorable temperature distribution on the chamber floor. This paper will discuss the methods used in the analysis, and the results obtained to determine the optimal configuration of these heaters on the chamber floor.

Wilhite, Jarred↗

Transient Heater Analysis for Orion Thermal Vacuum Testing

The Space Environments Complex (SEC) at NASA’s Plum Brook Station is currently being prepared to perform thermal vacuum testing of the Orion spacecraft. This thermal vacuum, or T-VAC test will be run for a period of 60 days, which will be the longest such test ever conducted at SEC. The Orion Crew Module (CM) and Service Module (SM) will undergo T-VAC testing in SEC’s Space Simulation Vacuum Chamber to ensure the functionality of these systems in a high vacuum environment at extremely cold temperatures. The T-VAC test setup in SEC was modeled and simulated in Thermal Desktop. The initial results from thermal analysis showed areas on the chamber floor to reach very low temperatures, which were below the minimum operating range of certain hardware located on or near the chamber floor. These hardware including elastomeric seals on the GN2 piping, bearing pads and O-rings are essential to both test and the operation of the SEC facility, and must be kept well above -20°F throughout the duration of the T-VAC test. Thus, further analysis was conducted to include the placement of patch heaters on the chamber floor in an effort to increase the temperature near colder areas on the floor. The results and findings from this analysis showed that using these heaters will result in a favorable temperature distribution on the chamber floor. This paper will discuss the methods used in the analysis, and the results obtained to determine the optimal configuration of these heaters on the chamber floor.

Wilhite, Jarred↗

Development of an Ablative 3D Quartz / Cyanate Ester Composite for the Orion Spacecraft Compression Pad

With the successful flight test of the Orion Multipurpose Crew Vehicle last December, NASA is well on its way to sending humans into deep space with the goal of putting astronauts on Mars in the 2030s. Orion will receive some upgrades for its next launch in 2018 including a newly developed 3D Quartz Cyanate Ester composite material for the compression pad. The compression pads are 10-inches in diameter and 3-inches thick. The pucks are at 4 locations in the heat shield that serve as a part of the mechanism for holding the Crew and Service modules together during most mission phases prior to separation followed by Earth re-entry. Thus the compression pad has structural, aerothermal and thermal protection requirements.This paper describes the approach used for developing the new 3D composite, including continuous 3D weaving on an automated loom followed by resin transfer molding. Mechanical, thermal and arc jet testing of the 3D composite are also described.

Feldman, Jay↗

Agile Approach to Assuring the Safety-Critical Embedded Software for NASA's Orion Spacecraft

Human-rated missions like those in NASA's Orion Program continue to grow in complexity. The role of software in achieving ambitious mission objectives has expanded dramatically in the last few decades. Assuring the safety and performance of the embedded flight software is quickly growing beyond the reach of traditional methods and resource levels. The methods used to build these software-dominant systems evolve in an on-going attempt to keep pace with the scope of our ambitions. Agile software development is now commonplace. The long timelines and large batches of work associated with traditional methods are being replaced by rapid delivery of small increments _ as system capabilities are realized in waves. Assurance of these critical software capabilities must therefore conquer an ever-expanding frontier of challenges, and do so with an approach matched to the evolving development methods. This paper recounts the journey of the Orion Independent Verification and Validation (IV&V) team as we addressed this dynamic environment. Widening our aperture to encompass a dramatically larger mission scope, while adjusting our cadence to synchronize with the rapid pace of agile software development, a new approach to IV&V is emerging. This approach is characterized by a sharper focus on mission capabilities, matched with a method to dynamically _follow the risk' as the IV&V team delivers more compelling assurance data in waves. Traditional methods prevalent in IV&V tend to scope the work using artifacts of the development process as they evolve from preliminary to final versions, and the pace of delivery was synchronized with the development timelines prevalent in the waterfall lifecycle. That more static approach is out of phase with the demands of the new environment. Scoping work according to the critical capabilities of the system (rather than artifacts of development) and synchronizing with the rapid pace of agile development, we are moving toward more effective parity with the demands of the environment. We explain the concrete steps we took, the principles that motivated our choices, and the results we have achieved to date.

Capability based assurance↗

Development of an Ablative 3D Quartz / Cyanate Ester Composite for the Orion Spacecraft Compression Pad

With the successful flight test of the Orion Multipurpose Crew Vehicle last December, NASA is well on its way to sending humans into deep space with the ultimate goal of putting astronauts on Mars in the 2030s. Orion will receive some upgrades for its next launch in 2018 including a newly developed 3D quartz / cyanate ester composite material for the compression pad. Multiple pad locations in the heat shield serve as a part of the mechanism for holding the Crew and Service Modules together during most mission phases prior to separation followed by Earth re-entry of the Crew Module. Thus the compression pad must survive structural and aerothermal loads, and protect the adjascent structure and heat shield materials from over-heating.This paper describes the approach used for developing the new 3D composite, including continuous 3D weaving on an automated loom followed by resin transfer molding. Mechanical, thermal, arc jet ,and stress relaxation testing of the 3D composite are also described.

Feldman, Jay D.↗

Dynamic Characterization of the Crew Module Uprighting System for NASA’s Orion Crew Module

The Orion Crew Module Uprighting System is a set of five airbag that are responsible for the uprighting of the crew module in the case of an inverted splashdown. A series of tests during the Underway Recovery Test 7 (URT-7) were run in preparation for the Artemis I mission, where the dynamic characterization of the CMUS in an ocean wave environment was performed. A Datawell Waverider DWR-G4 wave buoy was deployed to the characterize the wave environment during these tests. The heave measurements from this buoy were projected to the Orion Crew Module Buoyancy Test Article location by two different methods: (1) directly time-shifting the data, and (2) performing a frequency-domain, phase-shifting operation. Results demonstrate that the phase-shifting operation led to better correlation with the true crew module response to wave excitation as compared with the purely time-shifted method. Additionally, a novel approach to localize an object in a bidirectional wave field based on its heave response is presented and validated with URT- 7 data. Given a wave measurement device at a known location, one can estimate the relative distance to another object based solely off its heave response. Results show that if signals have sufficiently good correlation, this method can be used to estimate the relative separation between two objects in the same wave field.

Vertaska, Ivan Bertaska↗

An Agile-Like Approach to Hardware Development: The Ejectable Data Recorder (EDR) for Orion's Ascent Abort 2 (AA-2) Test Flight

On July 2, 2019, the Ascent Abort 2 (AA-2) Flight Test Vehicle was launched from Cape Canaveral, with the goal of demonstrating the performance of Orion’s Launch Abort System (LAS) and collecting data from hundreds of sensors throughout the vehicle. The data collected during this test flight is of paramount importance, as it will be used to certify the Orion vehicle for human spaceflight. Originally, the data was to be downlinked via a single string network of antennas on the LAS, with the associated risk of potential data dropouts, as well as loss of data once the LAS was jettisoned. Thus, additional antennas were added onto the crew module (CM) to support data downlink post-LAS jettison, a buffer rebroadcast capability was added to fill in any gaps in data downlink transmissions, and an ejectable data recorder (EDR) subsystem was added to the CM as a redundant measure to collect all the instrumentation data. The EDR subsystem was added to the project about one year after the project commenced, which significantly reduced the available development time when compared with the other subsystems of the AA-2 Test Flight. The project was further accelerated by six months, around the critical design review gate. Due to the schedule compression challenge and the fact that the EDR subsystem was a backup system and not flight critical, the EDR subsystem was further challenged to find a new and more efficient way to develop hardware. Thus, the EDR subsystem experimented with different management and systems engineering processes, team sizes, communication methods, and tools. Some examples are novel uses of SharePoint as a Data-centric Project Management & Systems Engineering environment, a continuous testing approach through the lifecycle, and a Skunkworks approach to managing the team. The EDR subsystem blended Commercial Off The Shelf (COTS) hardware with in-house developed hardware and software to create a novel data retrieval capability. The capability evolved rapidly through a hardware in the loop simulation environment that enabled incremental component updates for not only the EDR subsystem but across the entire Crew Module. This paper will present an overview of how the EDR subsystem was managed and compare it to an Agile approach to managing projects. The paper will further provide a recommended approach to future Agile-like hardware development that incorporates lessons learned from the EDR experience.

Agile↗

Development of Acoustic Mufflers for Cabin Noise Reduction in Orion Spacecraft

Controlling cabin acoustic noise levels in the Crew Module (CM) of the Orion spacecraft is critical to ensure adequate speech intelligibility, to avoid fatigue, and prevent any possibility of temporary and permanent hearing loss to the crew. The primary source of cabin noise for the on-orbit phase of the mission is from the Environmental Control and Life Support System (ECLSS) which recycles and conditions breathing air and maintains cabin pressurization through its duct network and components. Unfortunately, as a side effect, noise from the ECLSS fans propagates through theses ducts and emanate into the cabin habitable volume via the ECLSS inlet and outlets. To mitigate excessive duct-borne noise, two ECLSS mufflers have been designed to provide significant acoustic transmission loss (TL) so that the cabin noise requirements can be met. Each muffler is meant to be installed in the ducting of the ECLSS air inlet and outlet sides, respectively. Packaging constraints and tight volume requirements necessitated the mufflers to be of complex geometry and compatible with the bends of the ECLSS duct layout. To design and characterize the acoustic performance of the inlet and outlet mufflers, computational acoustic models were developed using the Finite Element Method (FEM) with 𝑤𝑎𝑣𝑒଺ vibroacoustic software. Characterization of the acoustic material and perforations in the mufflers were addressed with poroelastic theory. Once the mufflers were designed on paper and its TL predicted, prototypes of these mufflers were created using additive manufacturing. The muffler prototypes were subsequently tested for acoustic TL in the laboratory with various con-figurations of acoustic materials. Comparing the analytical predictions to the test performance yielded excellent correlation for acoustic TL and demonstrated significant broadband noise attenuation. The ECLSS mufflers are currently scheduled to be installed on the Artemis II Crew Module (CM) of the Orion spacecraft and will provide significant cabin comfort to crew during the mission.

Indranil Dandaroy↗

Absolute throughput calibration of multiple spherical crystals for the Orion High-REsolution X-ray spectrometer (OHREX)

We present absolute throughput analysis of several crystals for the Orion High-REsolution X-ray (OHREX) imaging crystal spectrometer using ray tracing and experimental measurements. The OHREX spectrometer is a high-resolution x-ray spectrometer designed to measure spectral line shapes at the Orion laser facility. The spectrometer is fielded with up to two spherical crystals simultaneously covering two independent spectral ranges. Each crystal has a nominal radius of curvature of R = 67.2 cm and is fielded at a nominal Bragg angle of 51.3°. To cover different bands of interest, several different crystals are available, including Ge (111), KAP, and several cuts of quartz, whose resolving power λ/Δλ exceeds 10 000. The calibrated response of the available crystals has previously been reported from measurements at the EBIT-I electron beam ion trap at Lawrence Livermore National Laboratory. Here, we model the absolute throughput of each crystal using ray tracing and verify the results using experimental data for the quartz (10¯11) crystal.

M. J. MacDonald↗

Early Systems Integration Strengthens Orion Medical Capabilities

The Orion spacecraft has significant mass and volume constraints, which limits resources that can be provided for medical use. Sharing of resources between vehicle systems is therefore required to meet design requirements. This presentation will illustrate resource sharing within the Orion vehicle using oxygen as a case study.

C Haas↗

IMUFDIR Tuning In Response To Structural Deformation Of The Orion Capsule

During system level Thermal Vacuum (TVAC) testing it was discovered that the pressure differential of the crew cabin in a vacuum would deflect the capsule slightly, causing significant misalignment of Orion’s three Inertial Measurement Units (IMUs). This phenomenon has been likened to a balloon expanding. When this misalignment was modeled in simulation as a function of atmospheric pressure, it was determined that the rate of deflection on reentry was significant enough to cause a mis-compare of the angular rates measured by the IMUs. This mis-comparison of the rates caused Orion’s Fault Detection Isolation and Recovery (FDIR) algorithm to falsely fail one of the IMUs. This manuscript will discuss how the IMUFDIR algorithm was detuned to be insensitive to these ballooning effects, while still meeting FDIR requirements to capture real faults in an IMU. All testing to validate this detuning was performed in a Six Degree of Freedom (6 DOF) Monte Carlo Simulation Environment.

Nicholas Rahaim↗

Artemis I Orion IMU Flight Performance

The Orion flight software’s parity algorithm runs onboard to verify all three OIMUs (Orion Inertial Measurement Units) are sensing relatively uniform rate and acceleration and to quickly identify any unit which is in significant disagreement with the other two units. During the Artemis-I Wet Dress Rehearsal tests and Launch Countdowns, one of the three OIMUs regularly reported an anomalous parity signature for a brief period of time during sensor warm up. This paper will review this anomalous performance on the pad and review flight data with the intent to supplement the findings of the initial root cause investigation. Outside of this start up behavior, initial investigation into Artemis I flight data did not reveal any behavior of the OIMUs outside of preflight expectations. Flight data from any significant parity events and relevant IMU calibrations will be presented. A brief discussion of impacts to future Artemis mission operations strategy will be provided.

Robert Earl↗

Orion's Powered Flight Guidance Performance During Artemis I

Artemis is NASA’s campaign to explore the Moon and beyond. Artemis I, the un-crewed exo-LEO test flight, was completed in 2022. The Artemis I mission provided the means to prove-out both vehicle and systems as a pre-cursor to more advanced missions. The Orion capsule and service module had to be capable of accurately executing all major orbital burns and numerous correction burns to successfully execute the mission profile. In support of this needed translation maneuver capability, a powered flight guidance algorithm has been designed that provides a number of guided burn options depending on the burn objective. Some of these guidance options are based on classic orbit transfer problems, such as Lambert's time-of-flight problem. Some are based on proven NASA heritage manned space programs like Apollo and Shuttle. Some are new concepts that fill unique niche requirements. All of these options are integrated into an architecture based on a proven Shuttle heritage design, with a simple closed-loop guidance strategy, that provides both modularity, simplicity and adaptability to future, as yet to be defined, mission profiles. This paper will summarize the performance of Orion’s orbital powered flight guidance during the mission.

space guidance↗