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NASA NTRS2004

Lessons Learned During Cryogenic Optical Testing of the Advanced Mirror System Demonstrators (AMSDs)

Optical testing in a cryogenic environment presents a host of challenges above and beyond those encountered during room temperature testing. The Advanced Mirror System Demonstrators (AMSDs) are 1.4 m diameter, ultra light-weight (<20 kg/mA2), off-axis parabolic segments. They are required to have 250 nm PV & 50 nm RMS surface figure error or less at 35 K. An optical testing system, consisting of an Instantaneous Phase Interferometer (PI), a diffractive null corrector (DNC), and an Absolute Distance Meter (ADM), was used to measure the surface figure & radius-of-curvature of these mirrors at the operational temperature within the X-Ray Calibration Facility (XRCF) at Marshall Space Flight Center (MSFC). The Ah4SD program was designed to improve the technology related to the design, fabrication, & testing of such mirrors in support of NASA s James Webb Space Telescope (JWST). This paper will describe the lessons learned during preparation & cryogenic testing of the AMSDs.

Hadaway, James↗

NASA NTRS2017

Lessons Learned: Mechanical Component and Tribology Activities in Support of Return to Flight

The February 2003 loss of the Space Shuttle Columbia resulted in NASA Management revisiting every critical system onboard this very complex, reusable space vehicle in a an effort to Return to Flight. Many months after the disaster, contact between NASA Johnson Space Center and NASA Glenn Research Center evolved into an in-depth assessment of the actuator drive systems for the Rudder Speed Brake and Body Flap Systems. The actuators are CRIT 1-1 systems that classifies them as failure of any of the actuators could result in loss of crew and vehicle. Upon further evaluation of these actuator systems and the resulting issues uncovered, several research activities were initiated, conducted, and reported to the NASA Space Shuttle Program Management. The papers contained in this document are the contributions of many researchers from NASA Glenn Research Center and Marshall Space Flight Center as part of a Lessons Learned on mechanical actuation systems as used in space applications. Many of the findings contained in this document were used as a basis to safely Return to Flight for the remaining Space Shuttle Fleet until their retirement.

Tribology↗

NASA NTRS2018

Spacecraft Micro-Vibration: A Survey of Problems, Experiences, Potential Solutions, and Some Lessons Learned

Predicting, managing, controlling, and testing spacecraft micro-vibrations due to on-board internal disturbance sources is a formidable multi-disciplinary systems engineering challenge, especially for those observatories hosting extremely sensitive optical sensor payloads with stringent requirements on allowable Line-of-Sight (LOS) jitter. In this paper some specific spacecraft micro-vibration engineering challenges will be introduced and described. Technical background context is provided with the inclusion of several illustrative examples of NASA and ESA missions (both past and present) where dynamic interactions have to be addressed and which have demanding payload instrument LOS jitter requirements. A general modeling, analysis, simulation, and test approach to address and solve the overall problem of spacecraft micro-vibrations is outlined. Recommended rules of thumb are presented to provide guidance for analysts on where to initiate and how to approach a new spacecraft micro-vibration design problem. A set of experience based spacecraft micro-vibration lessons learned are also presented in the hope they can be leveraged on new system development projects to help overcome unfamiliarity with previously identified micro-vibration technical pitfalls and challenges.

Alvarez-Salazar, Oscar S.↗

NASA NTRS2018

Spacecraft Micro-Vibration: A Survey of Problems, Experiences, Potential Solutions, and Some Lessons Learned

Predicting, managing, controlling, and testing spacecraft microvibrations due to on-board internal disturbance sources is a formidable multi-disciplinary systems engineering challenge, especially for those observatories hosting extremely sensitive optical sensor payloads with stringent requirements on allowable line-of-sight jitter. In this paper some specific spacecraft micro-vibration engineering challenges will be introduced and described. Technical background context is provided with the inclusion of several illustrative examples of NASA and European Space Agency missions (both past and present) where dynamic interactions have to be addressed and which have demanding payload instrument line-of-sight jitter requirements. A general modeling, analysis, simulation, and test approach to address and solve the overall problem of spacecraft micro-vibrations is outlined. Recommended rules of thumb are presented to provide guidance for analysts on where to initiate and how to approach a new spacecraft micro-vibration design problem. A set of experience-based spacecraft micro-vibration lessons learned are also presented in the hope they can be leveraged on new system development projects to help overcome unfamiliarity with previously identified microvibration technical pitfalls and challenges.

Dennehy, Cornelius↗

NASA NTRS1995

Space Mechanisms Lessons Learned Study. Volume 1: Summary

Hundreds of satellites have been launched to date. Some have operated extremely well and others have not. In order to learn from past operating experiences, a study was conducted to determine the conditions under which space mechanisms (mechanically moving components) have previously worked or failed. The study consisted of: (1) an extensive literature review that included both government contractor reports and technical journals; (2) communication and visits (when necessary) to the various NASA and DOD centers and their designated contractors (this included contact with project managers of current and prior NASA satellite programs as well as their industry counterparts); (3) requests for unpublished information to NASA and industry; and (4) a mail survey designed to acquire specific mechanism experience. The information obtained has been organized into two volumes. Volume 1 provides a summary of the lessons learned, the results of a needs analysis, responses to the mail survey, a listing of experts, a description of some available facilities and a compilation of references. Volume 2 contains a compilation of the literature review synopsis.

Shapiro, Wilbur↗

NASA NTRSDate not supplied

Mission Status, On-Orbit Performance, and Lessons Learned of the Global Ecosystem Dynamics Investigation (GEDI) Lidar Laser Transmitters

The Global Ecosystems Dynamics Investigation (GEDI) Lidar, is a global 3-dimensional biomass lidar instrument aboard the International Space Station (ISS) and the Japanese Experiment Module (JEM). Its core mission is to measure the global carbon balance of Earth’s forests with 3 laser transmitters using multi-beam waveform-capture methods. GEDI’s laser transmitter concept was originally funded by NASA Goddard’s Earth Science Technology Office (ESTO) for future Earth Altimetry and Lidar missions ~ 20 years ago, and after a long road of development, the first flight-ready unit was a 10 mJ-class system for GEDI’s ISS-based specifications. Furthermore, no adjustment in drive parameters has been required nor significant decay detected after 4 years of near continuous operation of 3 on-board lasers, which were designed for a 2-year mission. We report on the GEDI laser design process, their on-orbit performance, the major lessons learned, and some critical insight into our in-house flight quality development process that enabled their delivery within budget, schedule, and low risk extended mission life capability.

D. Barry Coyle↗

NASA NTRS2009

NASA Composite Materials Development: Lessons Learned and Future Challenges

Composite materials have emerged as the materials of choice for increasing the performance and reducing the weight and cost of military, general aviation, and transport aircraft and space launch vehicles. Major advancements have been made in the ability to design, fabricate, and analyze large complex aerospace structures. The recent efforts by Boeing and Airbus to incorporate composite into primary load carrying structures of large commercial transports and to certify the airworthiness of these structures is evidence of the significant advancements made in understanding and use of these materials in real world aircraft. NASA has been engaged in research on composites since the late 1960 s and has worked to address many development issues with these materials in an effort to ensure safety, improve performance, and improve affordability of air travel for the public good. This research has ranged from synthesis of advanced resin chemistries to development of mathematical analyses tools to reliably predict the response of built-up structures under combined load conditions. The lessons learned from this research are highlighted with specific examples to illustrate the problems encountered and solutions to these problems. Examples include specific technologies related to environmental effects, processing science, fabrication technologies, nondestructive inspection, damage tolerance, micromechanics, structural mechanics, and residual life prediction. The current state of the technology is reviewed and key issues requiring additional research identified. Also, grand challenges to be solved for expanded use of composites in aero structures are identified.

Tenney, Darrel R.↗

NASA NTRSDate not supplied

The NEXT-C Power Processing Unit: Lessons Learned from the Design, Build, and Test of the NEXT-C PPU for APL's DART Mission

NASA’s Double Asteroid Redirection Test (DART) will be the first-ever planetary defense mission to demonstrate asteroid deflection using kinetic impactor technology. The DART spacecraft will utilize the NASA Evolutionary Xenon Thruster (NEXT), which is a successor to the NSTAR ion propulsion system that successfully propelled NASA’s Deep Space 1 and Dawn spacecraft. In 2015, NASA partnered with Aerojet Rocketdyne and ZIN Technologies on the NEXT-Commercial (NEXT-C) effort to manufacture a Flight-Qualified (TRL 8) power processing unit (PPU). The NEXT-C PPU was based on the heritage gridded ion thruster PPU from NSTAR and NEXT, but with significant improvements in performance and manufacturability. The design goals of the NEXT-C PPU were to achieve the technical performance goals of the PPU in size, mass, and efficiency over a wide range of input voltage and output power. This paper discusses the lessons learned from the design, build, and test of the NEXT-C PPU, and how challenges were overcome to deliver a Flight PPU.

NEXT-C↗

NASA NTRSDate not supplied

The NEXT-C Power Processing Unit: Lessons Learned from the Design, Build, and Test of the NEXT-C PPU for APL's DART Mission

NEXT-C↗

NASA NTRSDate not supplied

Progress in Red vs. Green Propellant Operations: ASCENT Load Operations Lessons Learned

The Green Propellant Infusion Mission (GPIM) [1] is a NASA Space Technology Mission Directorate (STMD) effort to establish via demonstration ASCENT propellant (Advanced Space Craft Energetic Non-Toxic propellant, formerly referred to as AF-M315E) ground operations through on –orbit performance. ASCENT was developed by Air Force Research Laboratory (AFRL) as an increased energy density, reduced toxicity and reduced hazard monopropellant formulation relative to hydrazine. The GPIM team was led by Ball Aerospace and Technologies Corporation (BATC) as Program Management and Principal Investigator with AFRL, Aerojet-Rocketdyne (AR), the United States Space Force Space and Missile Systems Center (USSF/SMC), NASA Glenn Research Center (GRC), NASA Goddard Space Flight Center (GSFC), and NASA Kennedy Space Center (KSC) as Co-Investigators. The AFRL co-investigator role in the GPIM program was to develop the Propellant Ground Support Equipment (PGSE), associated Standard Operating Procedures (SOP) and Check Lists (CL), propellant load, propellant specification standard conventions and analysis methods, decontamination and waste disposal practices. This paper will discuss lessons learned in documentation, crew composition and readiness, equipment readiness, propellant readiness and potential improvements in the PGSE design.

Anthony P Zuttarelli↗

NASA NTRS2017

Lessons Learned from Preparing OSIRIS-REx Spectral Analog Samples for Bennu

NASA's OSIRIS-REx sample return mission launched on September 8th, 2016 to rendezvous with B-type asteroid (101955) Bennu in 2018. Type C and B asteroids have been linked to carbonaceous chondrites because of their similar visible - to - near infrared (VIS-NIR) spectral properties [e.g., 1,2]. The OSIRIS-REx Visible and Infrared Spectrometer (OVIRS) and the Thermal Emission Spectrometer (OTES) will make spectroscopic observations of Bennu during the encounter. Constraining the presence or absence of hydrous minerals (e.g., Ca-carbonate, phyllosilicates) and organic molecules will be key to characterizing Bennu [3] prior to sample site selection. The goal of this study was to develop a suite of analog and meteorite samples and obtain their spectral properties over the wavelength ranges of OVIRS (0.4- 4.3 micrometer) and OTES (5.0-50 micrometer). These spectral data were used to validate the mission science-data processing system. We discuss the reasoning behind the study and share lessons learned.

Schrader, D. L.↗

NASA NTRS2023

Lessons Learned From Evaluation and Mitigation of Space Charging Threat Due to Use of Isolated (Hybrid) Bearings on the Pace Ocean Color Instrument

A high precision, high resolution Ocean Color Instrument (OCI) was developed for the Plankton, Aerosol, Cloud ocean Ecosystem (PACE) mission which required the use of electrically isolated Hybrid Bearings (silicon nitride balls). While desirable for technical performance of the instrument, this application caused portions of the instrument to become electrically isolated and come under threat of space charging effects from charged particles and the resultant differential charging. An evaluation of the environment, susceptibility of the components, such as bearings and electronics, and mitigation strategies were performed. As part of that process, simulations of the charging environment, analysis of internal mechanism charging and prediction of most likely discharge paths, testing of the bearings for susceptibility as well as resulting damage were performed and analyzed. Additionally, a novel method to deal with charging was developed. Considerations for dealing with electrically isolated mechanisms, results of the above-mentioned efforts as well as lessons learned are presented.

space charging↗

NASA NTRS2009

An Overview of MODIS Calibration and Characterization and Lessons Learned

The Moderate Resolution Imaging Spectroradiometer (MODIS) is a key instrument for NASA's EOS missions. Two nearly identical copies have flown on the Terra and Aqua spacecraft for more than 9 years and 6 years since their launch in December 1999 and May 2002, respectively. MODIS observations and associated data products have been widely used by the science community and users worldwide for studies of Earth's system of land, oceans, and atmosphere. MODIS was developed based on the desire of the science community to extend and enhance heritage sensors' data records. It was designed with enhancements made over its heritage sensors in terms of its spectral, spatial, and radiometric characteristics. It is a cross-track scanning radiometer, that uses a two-sided scan mirror, collecting data in 36 spectral bands covering spectral regions of visible (VIS), near-infrared (NIR), short-wave infrared (SWIR), mid-wave infrared (MWIR), and long-wave infrared (LWIR). The VIS, NIR, and SWIR bands (bands 1-19 and 26), which make measurements of daytime surface reflected radiances, are referred to as the reflective solar bands (RSB). The MWIR and LWIR bands (20-25 and 27-36), which measure both the daytime and nighttime scene emissive radiances, are thus referred to as the thermal emissive bands (TEB). In this paper, we provide an overview of MODIS instrument calibration and characterization methodologies, activities, and results from pre-launch to post launch, with emphasis on the lessons learned from its design to on-orbit operation. Currently, both instruments are operated normally and all the on-orbit calibration activities are performed on a regular basis with some at slightly reduced frequencies. The TEB responses have been extremely stable with less than 0.3% change per year. For the RSB, the changes are wavelength and scan angle dependent with the largest changes in the VIS spectral bands. As both Terra and Aqua MODIS continue to operate beyond their prime missions, constant effort is still needed to maintain instrument and calibration and data product quality. This paper shows that the lessons from Terra MODIS design, test, and operation, have greatly benefitted Aqua MODIS. Because of this, Aqua MODIS overall performance is better than Terra MODIS. It is not surprising that lessons from MODIS calibration and characterization, from methodologies to on-orbit implementation, have also provided valuable information for the design and development of future earth observing missions/sensors, such as VHRS on the NPP and NPOESS, ABI on GOES-R, OLI on LDCM, and the reflective solar sensor on CLARREO.

Xiong, Xiaxiong↗

NASA NTRS1994

Lessons learned in deploying software estimation technology and tools

Developing a software product involves estimating various project parameters. This is typically done in the planning stages of the project when there is much uncertainty and very little information. Coming up with accurate estimates of effort, cost, schedule, and reliability is a critical problem faced by all software project managers. The use of estimation models and commercially available tools in conjunction with the best bottom-up estimates of software-development experts enhances the ability of a product development group to derive reasonable estimates of important project parameters. This paper describes the experience of the IBM Software Solutions (SWS) Toronto Laboratory in selecting software estimation models and tools and deploying their use to the laboratory's product development groups. It introduces the SLIM and COSTAR products, the software estimation tools selected for deployment to the product areas, and discusses the rationale for their selection. The paper also describes the mechanisms used for technology injection and tool deployment, and concludes with a discussion of important lessons learned in the technology and tool insertion process.

Panlilio-Yap, Nikki↗

NASA NTRS2018

Preventing Premature Death in the M&S Lifecycle: Lessons Learned from Resurrection and Modernization of a Space System Contamination Model

Models and simulations (M&S) are often developed to meet specific needs and unique requirements for a particular situation. Once the M&S is implemented for a specific case and questions are answered, the M&S may go dormant until a similar need arises again at a later time, perhaps months to years later. Possible modification of the M&S may be required, and issues may arise if the M&S is not well documented, captured, or available. This can severely limit the useful life of the M&S and hinder future development or enhancements. This situation occurred with an M&S tool that had been developed to determine the impact to space system performance due to the presence of molecular contaminant films accumulating on key spacecraft surfaces. The challenges and issues encountered when resurrecting, executing, and modernizing the tool will be presented as a case study. To stay ahead of tomorrow’s challenges, resources to create M&S tools must be utilized efficiently. Lessons learned from this case study will aid M&S developers and users in planning for proper maintenance, transfer, and capture of key M&S tools and knowledge to avoid increased cost, increased development time, and wasted resources for projects relying on M&S.

Seasly, Elaine↗

NASA NTRS2019

GOES I-M: A Retrospective Look at Image Navigation and Registration (INR), Jitter and Lessons Learned

The Geostationary Operational Environmental Satellite (GOES) I-M series of spacecraft was the second generation of United States meteorological observational platforms in geosynchronous orbit. They served as the principal Earth- viewing observational platforms for continuously monitoring dynamic weather events from the mid-1990s and into the 21st century. This paper will look back at the program framing key system attributes of the mission, which necessitated a multi-layered development approach to meet stringent meteorological instrument Line-of-Sight (LoS) pointing and pointing stability requirements. The overall approach involved understanding, correcting, and avoiding pointing errors across a broad frequency range including what would typically be called dynamic interaction and jitter. Background information will be provided covering the mission architecture and program drivers. The systems solution for man- aging and mitigating the deleterious influences of on-board disturbances in order to meet the challenging instrument LoS pointing and jitter requirements will be described, along with the ‘first of its kind’ Image Navigation and Registration system. A broad look back at the lessons learned that emerged from the GOES I- M experience will be presented, with the intent of capturing general and specific insights for developers of future missions having stringent payload instrument pointing requirements. These discussions will touch on such critical aspects as defining jitter and related pointing requirements, the importance of early system architectural decisions, understanding and reducing on-board disturbances, the balance of test and analysis, and the imperative for maximizing on-orbit operational flexibility in order to accommodate unexpected dynamic interactions.

Sudey, John↗

NASA NTRS1993

Phase 3 integrated water recovery testing at MSFC: Single loop test results and lessons learned

A series of tests has been conducted at the NASA Marshall Space Flight Center (MSFC) to evaluate the performance of the Space Station Freedom (SSF) water recovery system. Potable and urine reclamation processors were integrated with waste water generation equipment and sucessfully operated for a total of 144 days. This testing marked the first occasion in which the waste feed sources for the previous potable and hygiene loops were combined into a single loop and processed to potable water quality. Reclaimed potable water from the combined waste waters routinely met the SSF water quality specifications.In the last stage of testing, data was obtained that indicated that the water processor (WP) presterilizer may not be required to meet the potable water quality specification. The removal of the presterilizer from the Water Processor design would provide a significant power savings, though an increase in the residence time of the catalytic oxidation reactor may be required to meet the potable microbial and total Organic Carbon specifications. This paper summarizes the test objectives, system design, test activities/protocols, significant results/anomalies and major lessons learned.

Carter, Donald Layne↗

NASA NTRS2016

The Soil Moisture Acttive Passive Mission: Fault Protection Performance and Lessons Learned

Fault protection as a discipline involves a collection of flight software logic and operational processes for detecting unacceptable anomalous behavior, responding prior to reaching criticality, restricting the propagation of a failure beyond a fault containment region, and recovering the vehicle back to full or degraded functionality if possible. The System Fault Protection (SFP) design for the SMAP Earth orbiter was put to the test during its 90-day vehicle commissioning activities. During this time, the SFP software autonomously protected the vehicle from multiple faults to critical hardware, and the operations team successfully returned the observatory to its science state. The SFP also performed well in the presence of anomalous behavior below true safety limits by not taking unnecessary response actions, instead allowing the operations team time to monitor the behavior. Certain aspects of the SFP design were modified during operations via both parameter updates and a full flight software update in order to better match the vehicle behavior in the flight environment. An evaluation of the SMAP SFP performance during vehicle Commissioning will be provided in this paper, as well as a set of lessons learned largely focused on visibility, SFP mutability in operations, responses to peripheral device faults, and Safe Mode recovery and design. By capturing some of the knowledge gained during SMAP Commissioning, it is intended that this paper provide guidance for making future System Fault Protection designs more robust and supportive of operations.

Clark, Jessica↗