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Schedules and logic diagrams for ground support, testing, training, and management for advanced space transport program
Procedures, equipment, and analytical techniques were developed to implement the ground tested 2-hour protocol in-flight operations. The methods are: 1) The flight protocol incorporates additional safety margin over the ground tested protocol. This includes up to 20 min of additional time on enriched O2 during suit purge and pressure check, increased duration of extravehicular activity (EVA) preparation exercise during O2 prebreathing (up to 90 min vs; the tested 24 min), and reduced rates of depressurization. The ground test observations were combined with model projections of the conservative measures (using statistical models from Duke University and NASA JSQ to bound the risk of Type I and Type II decompression sickness (DCS). 2) An inflight exercise device using the in-flight ergometer and elastic tubes for upper body exercise was developed to replicate the dual cycle exercise in the ground trials. 3) A new in-flight breathing system was developed and man-tested. 4) A process to monitor inflight experience with the protocol, including the use of an in-suit Doppler bubble monitor when available, was developed. The results are: 1) The model projections of the conservative factors of the operational protocol were shown to reduce the risk of DCS to levels consistent with the observations of no DCS to date in the shuttle program. 2) Cross over trials of the dual cycle ergometer used in ground tests and the in-flight exercise system verified that02consumption and the % division of work between upper and lower body was not significantly different at the p= 0.05 level. 3) The in-flight breathing system was demonstrated to support work rates generating 75% O2(max) in 95 percentile subjects. 4) An in-flight monitoring plan with acceptance criteria was put in place for the 2-hour prebreathe protocol. And the conclusions are: The 2-hour protocol has been approved for flight, and all implementation efforts are in place to allow use of the protocol as early as flight ISS 7A, now scheduled in November of 2000.
The third flight of the Hyper-X Research Vehicle at nearly Mach 10 in November 2004 demonstrated the potential for airbreathing propulsion at hypersonic speeds. The flowpath of the scramjet engine used in the Hyper-X Research Vehicle was developed using computational fluid dynamic based design method in combination with a systematic series of ground tests in the NASA HyPulse Shock Tunnel at conditions duplicating Mach 10 flight. The test model was a true scale height and length of the internal flight engine flowpath that was partial width and truncated fore and aft. Tests were conducted using a mixture of hydrogen augmented with two-percent silane. Silane gas served as an ignition aid during the short duration of the pulse facility tests. The engine inflow values of pressure, temperature, and Mach number were parametrically varied during the ground test entries to broaden the database over the expected uncertainty in the flight conditions. A review of the ground test technique and comparisons of the ground test pressures along with selected data from the third flight are presented.
The National Force Measurement Technology Capability (NFMTC) is a nationwide partnership established in 2008 and sponsored by NASA’s Aeronautics Evaluation and Test Capabilities (AETC) project to maintain and further develop force and angle measurement capabilities primarily for NASA’s ground test facilities. One of the NFMTC’s primary objectives is to develop new force and angle measurement capabilities to meet the needs of researchers testing in NASA’s ground test facilities. This work will highlight several new capabilities that are either at or near operational readiness. A new six-component flow-through balance was designed and fabricated to support an upcoming retropropulsion test campaign at the NASA Langley Unitary Plan Wind Tunnel. The balance employs membranes in place of bellows, which have historically been used, and passes the flow through load bearing parts of the balance. Flow through the balance is optimized via the addition of flow guides, which are manufactured as separate parts, and attached to the balance. Calibration of this new flow-through balance demonstrates that it can suitably characterize the load and pressure ranges it was designed for, which provides aero researchers a new tool to directly measure retropropulsion performance of powered descent vehicles. Balances used in NASA’s ground test facilities are typically either single-piece balances or floating-frame balances. Historically, these two types of balances have generally used different front-end (model) attachments. Single-piece balances generally have a cylindrical front end that is forward of any measuring sections and at a reduced diameter relative to the balance outer diameter. Floating-frame balances generally have front end fits that extend over one or more measuring sections and that engage at the balance outer diameter. Recently, the NFMTC fabricated a single-piece balance with a front end fit that is compatible with the hardware used to calibrate floating-frame balances. Calibration results evaluating this front end fit will be presented. From a recent survey of angle measurement needs, the development of smaller angle measurement packages was identified as one area of improvement. Micro-electromechanical systems (MEMS) are continually being refined to provide high performance accelerometers that are a fraction of the volume of the quartz flexure based accelerometers that are standard in wind tunnels. A survey of commercial off-the-shelf MEMS accelerometers was conducted, and it identified the Safran Colibrys MS lines to be of adequate performance. Single-axis test boards and tri-axis rigid-flex production boards were designed and fabricated with a volume of approximately .18 cubic inches. The boards were designed to provide all the necessary conditioning for the MEMS accelerometers at levels to meet or exceed all requirements for the MS line sensors. Preliminary testing of these assembled sensor packages has demonstrated acceptable performance for wind-tunnel angle measurement. Several new rotating balances are at various stages of completion for NASA Glenn Research Center’s fan drive rigs. These balances provide direct measurement of thrust and torque of a driven fan or fan section to provide an estimate of fan efficiency and net thrust. Three two-component balances have been recently completed, and one six-component balance is in active development. A custom rotating telemetry system has been developed to support testing with these balances, and the telemetry system is integrated into the forward end of each one. The telemetry system is designed to remove mechanical sliprings by using an optical ethernet-based slipring for data transmission.
The Adaptive Compliant Trailing Edge (ACTE) flap was flown on the National Aeronautics and Space Administration (NASA) Gulfstream GIII testbed at the NASA Armstrong Flight Research Center. This smoothly curving flap replaced the existing Fowler flaps creating a seamless control surface. This compliant structure, developed by FlexSys Inc. in partnership with the Air Force Research Laboratory, supported NASA objectives for airframe structural noise reduction, aerodynamic efficiency, and wing weight reduction through gust load alleviation. A thorough structures airworthiness approach was developed to move this project safely to flight. A combination of industry and NASA standard practice require various structural analyses, ground testing, and health monitoring techniques for showing an airworthy structure. This paper provides an overview of compliant structures design, the structural ground testing leading up to flight, and the flight envelope expansion and monitoring strategy. Flight data will be presented, and lessons learned along the way will be highlighted.
This report is a summary of the ground vibration testing of the TiltRotor Aeroelastic Stability Testbed (TRAST). The U.S. Army has developed this new tiltrotor model system to validate whirl flutter stability analysis, a critical instability mechanism in this type of aircraft. As such, component-level vibration testing is critical to creating and validating analytical models. This report includes experimental vibration testing results from component level to the full model system. In addition, experimentally measured stiffness values are reported for key components of the model.
Although extensive ground testing, utilizing both the Captive Trajectory system (CTS) and grid method, generally precedes flight testing of new aircraft/weapon combinations, the flight test results often do not match the wind tunnel predictions. These discrepancies are generally attributed to model scale, wind tunnel test errors and Reynolds Number effects, and may have been the cause of several previous aircraft/weapon incidents. The paper describes the procedure used at the Naval Air Warfare Center, Aircraft Division, Warminster (NAWCADWAR) during the early phases of wind tunnel testing and analysis, as well as subsequent flight testing to validate the predicted trajectories. This approach is designed to improve the safety of the flight tests for the critical portions of the aircraft envelope.
Overview of ground test techniques used for aerodynamic characterization from supersonic to subsonic speeds.
Conventional end-to-end ground tests for verification of control system performance become increasingly complicated with the development of large, multiple flexible body spacecraft structures. The expense of accurately reproducing the on-orbit dynamic environment and the attendant difficulties in reducing and accounting for ground test effects limits the value of these tests. TRW has developed a building block approach whereby a combination of analysis, simulation, and test has replaced end-to-end performance verification by ground test. Tests are performed at the component, subsystem, and system level on engineering testbeds. These tests are aimed at authenticating models to be used in end-to-end performance verification simulations: component and subassembly engineering tests and analyses establish models and critical parameters, unit level engineering and acceptance tests refine models, and subsystem level tests confirm the models' overall behavior. The Precision Control of Agile Spacecraft (PCAS) project has developed a control structural interaction testbed with a multibody flexible structure to investigate new methods of precision control. This testbed is a model for TRW's approach to verifying control system performance. This approach has several advantages: (1) no allocation for test measurement errors is required, increasing flight hardware design allocations; (2) the approach permits greater latitude in investigating off-nominal conditions and parametric sensitivities; and (3) the simulation approach is cost effective, because the investment is in understanding the root behavior of the flight hardware and not in the ground test equipment and environment.
Arcjet and ion propulsion offer potentially significant reductions in the mass of propulsion systems required for Earth orbiting satellites and planetary spacecraft. For this reason, they have been the subject of validation and demonstration programs. After examining the benefits of electric propulsion, this paper discusses the technology base for the Electric propulsion Space Experiment (ESEX) arcjet demonstration experiment and the NASA SEP Technology Application Readiness (NSTAR) ion propulsion validation program. As part of the Advanced Research and Global Observation Spacecraft (ARGOS), ESEX will perform ten 15-minute firings of a 30 kW ammonia arcjet. NASA's validation program, NSTAR, consists of two major elements: a ground-test element and an in-space experiment. The ground-test element will validate the life, intergrability, and performance of low-power ion propulsion. The in-space element will demonstrate the feasibility of integrating and flying an ion propulsion system. The experiment will measure the interactions among the ion propulsion system, the host spacecraft, and the surrounding space plasma; and it will provide a quantitative assessment of the ability of ground testing to replicate the in-space performance of ion thrusters. By involving industry in NSTAR, a commercial source for this technology will be ensured. Furthermore, the successful completion of the NSTAR validation program will stimulate commercial and government (both civilian and military) uses of this technology.
For the first time in nearly 30 years, NASA is developing a new manned space flight launch system. The Ares I will carry crew and cargo to not only the International Space Station, but onward for the future exploration of the Moon and Mars. The Ares I control system and structural designs use complex computer models for their development. An Integrated Vehicle Ground Vibration Test (IVGVT) will validate the efficacy of these computer models. The IVGVT will reduce the technical risk of unexpected conditions that could place the vehicle or crew in jeopardy. The Ares Project Office's Flight and Integrated Test Office commissioned a study to determine how historical programs, such as Saturn and Space Shuttle, validated the structural dynamics of an integrated flight vehicle. The study methodology was to examine the historical record and seek out members of the engineering community who recall the development of historic manned launch vehicles. These records and interviews provided insight into the best practices and lessons learned from these historic development programs. The information that was gathered allowed the creation of timelines of the historic development programs. The timelines trace the programs from the development of test articles through test preparation, test operations, and test data reduction efforts. These timelines also demonstrate how the historical tests fit within their overall vehicle development programs. Finally, the study was able to quantify approximate staffing levels during historic development programs. Using this study, the Flight and Integrated Test Office was able to evaluate the Ares I Integrated Vehicle Ground Vibration Test schedule and workforce budgets in light of the historical precedents to determine if the test had schedule or cost risks associated with it.
This paper 1) documents findings and observations from the American Institute of Aeronautics and Astronautics (AIAA) Ground Test Technical Committee (GTTC) Future of Ground Test Working Group and the Applied Aeronautics Technical Committee (APATC) Collaborative Experiments & Computation Discussion Group, and 2) develops a more focused approach for sharing and advancing integrated development and use of physical experimental and computational capabilities for aerospace research and development. The GTTC and APATC are engaging with the larger AIAA technical community by creating a Focus Group on this topical area that will support working together on common interests in the public domain. This paper summarizes the knowledge capture from the last ten+ years and proposes a structure and scope going forward for the new, combined Focus Group.
A detailed experimental and analytical evaluation was performed to define the response of TD nickel chromium alloy (20 percent chromium) and coated columbium (R512E on CB-752 and VH-109 on WC129Y) to shuttle orbiter reentry heating. Flight conditions important to the response of these thermal protection system (TPS) materials were calculated, and test conditions appropriate to simulation of these flight conditions in flowing air ground test facilities were defined. The response characteristics of these metallics were then evaluated for the flight and representative ground test conditions by analytical techniques employing appropriate thermochemical and thermal response computer codes and by experimental techniques employing an arc heater flowing air test facility and flat face stagnation point and wedge test models. These results were analyzed to define the ground test requirements to obtain valid TPS response characteristics for application to flight. For both material types in the range of conditions appropriate to the shuttle application, the surface thermochemical response resulted in a small rate of change of mass and a negligible energy contribution. The thermal response in terms of surface temperature was controlled by the net heat flux to the surface; this net flux was influenced significantly by the surface catalycity and surface emissivity. The surface catalycity must be accounted for in defining simulation test conditions so that proper heat flux levels to, and therefore surface temperatures of, the test samples are achieved.
The NASA Dryden Flight Research Facility performs ground vibration testing to assess the structural characteristics of new and modified research vehicles. This paper updates the research activities, techniques used, and experiences in applying this technology to aircraft since 1987. Test equipment, data analysis methods, and test procedures used for typical test programs are discussed. The data presented illustrate the use of modal test and analysis in flight research programs for a variety of aircraft. This includes a technique to acquire control surface free-play measurements on the X-31 airplane more efficiently, and to assess the effects of structural modifications on the modal characteristics of an F-18 aircraft. In addition, the status and results from current research activities are presented. These data show the effectiveness of the discrete modal filter as a preprocessor to uncouple response measurements into simple single-degree-of-freedom responses, a database for the comparison of different excitation methods on a JetStar airplane, and the effect of heating on modal frequency and damping.
Nuclear Thermal Propulsion (NTP) is a concept which uses a nuclear reactor to heat a propellant to high temperatures without combustion and can achieve significantly greater specific impulse than chemical engines. NTP has been considered many times for human and cargo missions beyond low earth orbit. A lot of development and technical maturation of NTP components took place during the Rover/NERVA program of the 60's and early 70's. Other NTP programs and studies followed attempting to further mature the NTP concept and identify a champion customer willing to devote the funds and support the development schedule to a demonstration mission. Budgetary constraints require the use of an affordable development and qualification strategy that takes into account all the previous work performed on NTP to construct an existing database, and include lessons learned and past guidelines followed. Current guidelines and standards NASA uses for human rating chemical rocket engines is referenced. The long lead items for NTP development involve the fuel elements of the reactor and ground testing the engine system, subsystem, and components. Other considerations which greatly impact the development plans includes the National Space Policy, National Environmental Policy Act, Presidential Directive/National Security Council Memorandum #25 (Scientific or Technological Experiments with Possible Large-Scale Adverse Environmental Effects and Launch of Nuclear Systems into Space), and Safeguards and Security. Ground testing will utilize non-nuclear test capabilities to help down select components and subsystems before testing in a nuclear environment to save time and cost. Existing test facilities with minor modifications will be considered to the maximum extent practical. New facilities will be designed to meet minimum requirements. Engine and test facility requirements are based on the driving mission requirements with added factors of safety for better assurance and reliability. Emphasis will be placed on small engines, since the smaller the NTP engine, the easier it is to transport, assemble/disassemble, and filter the exhaust during tests. A new ground test concept using underground bore holes (modeled after the underground nuclear test program) to filter the NTP engine exhaust is being considered. The NTP engine system design, development, test, and evaluation plan includes many engine components and subsystems, which are very similar to those used in chemical engines, and can be developed in conjunction with them Other less mature NTP engine components and subsystems (e.g., reactor) will be thoroughly analyzed and tested to acceptable levels recommended by the referenced standards and guidelines. The affordable development strategy also considers a prototype flight test, as a final step in the development process. Preliminary development schedule estimates show that an aggressive development schedule (without much margin) will be required to be flight ready for a 2033 human mission to Mars.
Nuclear Thermal Propulsion (NTP) is a concept which uses a nuclear reactor to heat a propellant to high temperatures without combustion and can achieve significantly greater specific impulse than chemical engines. NTP has been considered many times for human and cargo missions beyond low earth orbit. A lot of development and technical maturation of NTP components took place during the Rover/NERVA program of the 60's and early 70's. Other NTP programs and studies followed attempting to further mature the NTP concept and identify a champion customer willing to devote the funds and support the development schedule to a demonstration mission. Budgetary constraints require the use of an affordable development and qualification strategy that takes into account all the previous work performed on NTP to construct an existing database, and include lessons learned and past guidelines followed. Current guidelines and standards NASA uses for human rating chemical rocket engines is referenced. The long lead items for NTP development involve the fuel elements of the reactor and ground testing the engine system, subsystem, and components. Other considerations which greatly impact the development plans includes the National Space Policy, National Environmental Policy Act, Presidential Directive/National Security Council Memorandum #25 (Scientific or Technological Experiments with Possible Large-Scale Adverse Environmental Effects and Launch of Nuclear Systems into Space), and Safeguards and Security. Ground testing will utilize non-nuclear test capabilities to help down select components and subsystems before testing in a nuclear environment to save time and cost. Existing test facilities with minor modifications will be considered to the maximum extent practical. New facilities will be designed to meet minimum requirements. Engine and test facility requirements are based on the driving mission requirements with added factors of safety for better assurance and reliability. Emphasis will be placed on small engines, since the smaller the NTP engine, the easier it is to transport, assemble/disassemble, and filter the exhaust during tests. A new ground test concept using underground bore holes (modeled after the underground nuclear test program) to filter the NTP engine exhaust is being considered. The NTP engine system design, development, test, and evaluation plan includes many engine components and subsystems, which are very similar to those used in chemical engines, and can be developed in conjunction with them Other less mature NTP engine components and subsystems (e.g., reactor) will be thoroughly analyzed and tested to acceptable levels recommended by the referenced standards and guidelines. The affordable development strategy also considers a prototype flight test, as a final step in the development process. Preliminary development schedule estimates show that an aggressive development schedule (without much margin) will be required to be flight ready for a 2033 human mission to Mars.
The objective of this research was to calibrate the ground-to-space effective atomic oxygen fluence for DC 93-500 silicone in a thermal energy electron cyclotron resonance (ECR) oxygen plasma facility. Silicones, commonly used spacecraft materials, do not chemically erode with atomic oxygen attack like other organic materials but form an oxidized hardened silicate surface layer. Therefore, the effective atomic oxygen fluence in a ground test facility should not be determined based on mass loss measurements, as they are with organic polymers. A technique has been developed at the Glenn Research Center to determine the equivalent amount of atomic oxygen exposure in an ECR ground test facility to produce the same degree of atomic oxygen damage as in space. The approach used was to compare changes in the surface hardness of ground test (ECR) exposed DC 93-500 silicone with DC 93-500 exposed to low Earth orbit (LEO) atomic oxygen as part of a shuttle flight experiment. The ground to in-space effective atomic oxygen fluence correlation was determined based on the fluence in the ECR source that produced the same hardness for the fluence in-space. Nanomechanical hardness versus contact depth measurements were obtained for five ECR exposed DC 93-500 samples (ECR exposed for 18 to 40 hrs, corresponding to Kapton effective fluences of 4.2 x 10(exp 20) to 9.4 x 10(exp 20) atoms/sq cm, respectively) and for space exposed DC 93-500 from the Evaluation of Oxygen Interactions with Materials III (EOIM III) shuttle flight experiment, exposed to LEO atomic oxygen for 2.3 x 10(exp 20) atoms/sq cm. Pristine controls were also evaluated. A ground-to-space correlation value was determined based on correlation values for four contact depths (150, 200, 250, and 300 nm), which represent the near surface depth data. The results indicate that the Kapton effective atomic oxygen fluence in the ECR facility needs to be 2.64 times higher than in LEO to replicate equivalent exposure damage in the ground test silicone as occurred in the space exposed silicone.
This paper presents the preliminary performance results of the artificial intelligence monitoring system in full operational mode using near real time acceleration data downlinked from the International Space Station. Preliminary microgravity environment characterization analysis result for the International Space Station (Increment-2), using the monitoring system is presented. Also, comparison between the system predicted performance based on ground test data for the US laboratory "Destiny" module and actual on-orbit performance, using measured acceleration data from the U.S. laboratory module of the International Space Station is presented. Finally, preliminary on-orbit disturbance magnitude levels are presented for the Experiment of Physics of Colloids in Space, which are compared with on ground test data. The ground test data for the Experiment of Physics of Colloids in Space were acquired from the Microgravity Emission Laboratory, located at the NASA Glenn Research Center, Cleveland, Ohio. The artificial intelligence was developed by the NASA Glenn Principal Investigator Microgravity Services Project to help the principal investigator teams identify the primary vibratory disturbance sources that are active, at any moment of time, on-board the International Space Station, which might impact the microgravity environment their experiments are exposed to. From the Principal Investigator Microgravity Services' web site, the principal investigator teams can monitor via a dynamic graphical display, implemented in Java, in near real time, which event(s) is/are on, such as crew activities, pumps, fans, centrifuges, compressor, crew exercise, structural modes, etc., and decide whether or not to run their experiments, whenever that is an option, based on the acceleration magnitude and frequency sensitivity associated with that experiment. This monitoring system detects primarily the vibratory disturbance sources. The system has built-in capability to detect both known and unknown vibratory disturbance sources. Several soft computing techniques such as Kohonen's Self-Organizing Feature Map, Learning Vector Quantization, Back-Propagation Neural Networks, and Fuzzy Logic were used to design the system.