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At least 577 records · Page 32

Autonomous rendezvous and capture development infrastructure

In the development of the technology for autonomous rendezvous and docking, key infrastructure capabilities must be used for effective and economical development. This involves facility capabilities, both equipment and personnel, to devise, develop, qualify, and integrate ARD elements and subsystems into flight programs. One effective way of reducing technical risks in developing ARD technology is the use of the ultimate test facility, using a Shuttle-based reusable free-flying testbed to perform a Technology Demonstration Test Flight which can be structured to include a variety of additional sensors, control schemes, and operational approaches. This conceptual testbed and flight demonstration will be used to illustrate how technologies and facilities at MSFC can be used to develop and prove an ARD system.

Bryan, Thomas C.↗

NASP - Focus on technology

The major changes in the NASP program caused mostly by budget pressures are described and current technology developments are highlighted. Particular attention is given to the program funding, vehicle and engine design, and the technology program. It is concluded that the success of the X-30 vehicle design depends on the success of the technology development effort. The major accomplishments of the NASP technology program include the T-5 Shock Tunnel at California Institute of Technology and Mach 16 injection and mixing experiments conducted in this facility; the low speed component integration rig which provide data on engine operation from static conditions to Mach 3.5; the module to module interaction test which provided data on the effects of inlet unstart in one engine module on an adjacent module at Mach 4.3; and the direct-connect module used for fuel injection and mixing studies at Mach 6-8.

Waldman, Barry J.↗

The 3-D CFD modeling of gas turbine combustor-integral bleed flow interaction

An advanced 3-D Computational Fluid Dynamics (CFD) model was developed to analyze the flow interaction between a gas turbine combustor and an integral bleed plenum. In this model, the elliptic governing equations of continuity, momentum and the k-e turbulence model were solved on a boundary-fitted, curvilinear, orthogonal grid system. The model was first validated against test data from public literature and then applied to a gas turbine combustor with integral bleed. The model predictions agreed well with data from combustor rig testing. The model predictions also indicated strong flow interaction between the combustor and the integral bleed. Integral bleed flow distribution was found to have a great effect on the pressure distribution around the gas turbine combustor.

Chen, D. Y.↗

Embracing Safe Ground Test Facility Operations and Maintenance

Conducting integrated operations and maintenance in wind tunnel ground test facilities requires a balance of meeting due dates, efficient operation, responsiveness to the test customer, data quality, effective maintenance (relating to readiness and reliability), and personnel and facility safety. Safety is non-negotiable, so the balance must be an "and" with other requirements and needs. Pressure to deliver services faster at increasing levels of quality in under-maintained facilities is typical. A challenge for management is to balance the "need for speed" with safety and quality. It s especially important to communicate this balance across the organization - workers, with a desire to perform, can be tempted to cut corners on defined processes to increase speed. Having a lean staff can extend the time required for pre-test preparations, so providing a safe work environment for facility personnel and providing good stewardship for expensive National capabilities can be put at risk by one well-intending person using at-risk behavior. This paper documents a specific, though typical, operational environment and cites management and worker safety initiatives and tools used to provide a safe work environment. Results are presented and clearly show that the work environment is a relatively safe one, though still not good enough to keep from preventing injury. So, the journey to a zero injury work environment - both in measured reality and in the minds of each employee - continues. The intent of this paper is to provide a benchmark for others with operational environments and stimulate additional sharing and discussion on having and keeping a safe work environment.

Dunn, Steven C.↗

Breaking the Cost Curve: Applying Lessons Learned from the James Webb Space Telescope Development to Build More Cost-Effective Large Space Telescopes in the Future

This paper looks at the key programmatic and technical drivers of the James Webb Space Telescope and assesses ways to building more cost-effective telescopes in the future. The paper evaluates the top level programmatics for JWST along with the key technical drivers from design through integration and testing. Actual data and metrics from JWST are studied to identify what ultimately drove cost on JWST. Finally, the paper assesses areas where applying lessons learned can reduce costs on future observatories and will provide better insights into critical areas to optimize for cost.

ATLAST↗

Breaking the Cost Curve: Applying Lessons Learned from the James Webb Space Telescope Development

This paper looks at the key programmatic and technical drivers of the James Webb Space Telescope and assesses ways to building more cost-effective telescopes in the future. The paper evaluates the top level programmatics for JWST along with the key technical drivers from design through integration and testing. Actual data and metrics from JWST are studied to identify what ultimately drove cost on JWST. Finally, the paper assesses areas where applying lessons learned can reduce costs on future observatories and will provide better insights into critical areas to optimize for cost.

Feinberg, Lee↗

A Risk Analysis Tool for Estimating the Risk of Electrical Failures Due to Human Induced Defects

Aerospace electrical systems are required to withstand and adequately operate in extremely harsh environments that include, for example, high radiation exposure, temperature extremes, intense vibrational stress and drastic temperature cycling. The nature of aerospace electronics also demands high reliability since, with very few exceptions, there is no chance for hardware servicing or repairs. Common risk mitigation techniques for this type of situation are to perform a Reliability Analysis of the system throughout the development cycle, and to use electrical components that are regarded as “high reliability” because of additional controls and requirements applied in their design, manufacturing and testing. Unfortunately, studies have shown that even though these techniques are used, many systems fail to meet mission requirements well before the predicted lifetimes. This paper presents the analysis of failures of electrical parts, experienced during various stages of system development, at NASA Goddard Space Flight Center, Greenbelt MD, between the years 2001 and 2013. These components were subjected to qualification, screening and testing in which the goal was to ensure that the components would survive the stresses of the mission. The analysis categorizes failures by part type and failure mechanisms. One of the results of the analysis was the realization that a surprising proportion of failures experienced during system integration and testing were caused by human error (i.e. human induced defect). Further analysis included the determination of root failure mechanisms and any influencing factors contributing to these failures. The major causes of these defects were attributed to electrostatic damage (ESD), electrical overstress (EOS), mechanical overstress (MOS), and thermal overstress (TOS). Finally, the study proposes a risk analysis tool which incorporates these major causes for the failures, termed error-producing conditions (EPCs), and a proportionality factor representing the number of each type of failure that has occurred at the facility under study. These factors are quantified and used to communicate the risk of human induced defects for the assembly, integration and testing of space hardware based on the system’s electrical parts list. The new risk identification can trigger risk-mitigating actions more effectively, based on the presence of component categories or other hazardous conditions that have a history of failure due to human error.

Majewicz, Peter J.↗

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

A Description of the Software Element of the NASA EME Flight Tests

In support of NASA's Fly-By-Light/Power-By-Wire (FBL/PBW) program, a series of flight tests were conducted by NASA Langley Research Center in February, 1995. The NASA Boeing 757 was flown past known RF transmitters to measure both external and internal radiated fields. The aircraft was instrumented with strategically located sensors for acquiring data on shielding effectiveness and internal coupling. The data are intended to support computational and statistical modeling codes used to predict internal field levels of an electromagnetic environment (EME) on aircraft. The software was an integral part of the flight tests, as well as the data reduction process. The software, which provided flight test instrument control, data acquisition, and a user interface, executes on a Hewlett Packard (HP) 300 series workstation and uses BP VEEtest development software and the C programming language. Software tools were developed for data processing and analysis, and to provide a database organized by frequency bands, test runs, and sensors. This paper describes the data acquisition system on board the aircraft and concentrates on the software portion. Hardware and software interfaces are illustrated and discussed. Particular attention is given to data acquisition and data format. The data reduction process is discussed in detail to provide insight into the characteristics, quality, and limitations of the data. An analysis of obstacles encountered during the data reduction process is presented.

Koppen, Sandra V.↗

Application of digital terrain data to quantify and reduce the topographic effect on LANDSAT data

Integration of LANDSAT multispectral scanner (MSS) data with 30 m U.S. Geological Survey (USGS) digital terrain data was undertaken to quantify and reduce the topographic effect on imagery of a forested mountain ridge test site in central Pennsylvania. High Sun angle imagery revealed variation of as much as 21 pixel values in data for slopes of different angles and aspects with uniform surface cover. Large topographic effects were apparent in MSS 4 and 5 was due to a combination of high absorption by the forest cover and the MSS quantization. Four methods for reducing the topographic effect were compared. Band ratioing of MSS 6/5 and MSS 7/5 did not eliminate the topographic effect because of the lack of variation in MSS 4 and 5 radiances. The three radiance models examined to reduce the topographic effect required integration of the digital terrain data. Two Lambertian models increased the variation in the LANDSAT radiances. The nonLambertian model considerably reduced (86 per cent) the topographic effect in the LANDSAT data. The study demonstrates that high quality digital terrain data, as provided by the USGS digital elevation model data, can be used to enhance the utility of multispectral satellite data.

Justice, C. O.↗

Integration of Engine, Plume, and CFD Analyses in Conceptual Design of Low-Boom Supersonic Aircraft

This paper documents an integration of engine, plume, and computational fluid dynamics (CFD) analyses in the conceptual design of low-boom supersonic aircraft, using a variable fidelity approach. In particular, the Numerical Propulsion Simulation System (NPSS) is used for propulsion system cycle analysis and nacelle outer mold line definition, and a low-fidelity plume model is developed for plume shape prediction based on NPSS engine data and nacelle geometry. This model provides a capability for the conceptual design of low-boom supersonic aircraft that accounts for plume effects. Then a newly developed process for automated CFD analysis is presented for CFD-based plume and boom analyses of the conceptual geometry. Five test cases are used to demonstrate the integrated engine, plume, and CFD analysis process based on a variable fidelity approach, as well as the feasibility of the automated CFD plume and boom analysis capability.

Li, Wu↗

JMOSFET: A MOSFET parameter extractor with geometry-dependent terms

The parameters from metal-oxide-silicon field-effect transistors (MOSFETs) that are included on the Combined Release and Radiation Effects Satellite (CRRES) test chips need to be extracted to have a simple but comprehensive method that can be used in wafer acceptance, and to have a method that is sufficiently accurate that it can be used in integrated circuits. A set of MOSFET parameter extraction procedures that are directly linked to the MOSFET model equations and that facilitate the use of simple, direct curve-fitting techniques are developed. In addition, the major physical effects that affect MOSFET operation in the linear and saturation regions of operation for devices fabricated in 1.2 to 3.0 mm CMOS technology are included. The fitting procedures were designed to establish single values for such parameters as threshold voltage and transconductance and to provide for slope matching between the linear and saturation regions of the MOSFET output current-voltage curves. Four different sizes of transistors that cover a rectangular-shaped region of the channel length-width plane are analyzed.

Buehler, M. G.↗

Heavy Duty Natural Gas Single Cylinder Research Engine Installation, Commissioning, and Baseline Testing

Natural Gas (NG) Internal Combustion Engines (ICE) are a promising alternative to diesel engines for on-road heavy-duty applications to reduce greenhouse gas and harmful pollutant emissions. NG engines have not been widely adopted due to the lower thermal efficiency compared with diesel engine counterparts. To develop the base knowledge required to reach the desired efficiency, a Single Cylinder Engine (SCE) is the most effective platform to acquire reliable and repeatable data. A SCE test cell was developed using a Cummins 15-liter six-cylinder heavy-duty engine block modified to fire one cylinder (2.5-liter displacement). A Woodward Large Engine Control Module (LECM) is integrated to permit implementation of real-time advanced combustion control. Intake and exhaust characteristics, fuel composition, and exhaust gas recirculated substitution rate (EGR) are fully adjustable. A high-speed data acquisition system acquires in-cylinder, intake, and exhaust pressure for combustion analysis. The baseline testing shows reliable and consistent results for engine thermal efficiency, indicated mean effective pressure (IMEP), and coefficient of variance of the IMEP over a wide range of operating conditions while achieving effective control of all engine control and operation variables. This test cell will be used to conduct a research program to develop new and innovative control algorithms and CFD optimized combustion chamber designs, allowing ultra-high efficiency and low emissions for NG ICE heavy-duty on-road applications.

03 NATURAL GAS↗

Test chips and ASIC qualification

A test chip set being developed to aid in the qualification of spaceborne Application Specific Integrated Circuits (ASICs) is described. The chip set consists of a process monitor for process parameter verification, a fault chip for yield analysis, a reliability chip for ASIC failure rate analysis, and total ionizing dose and single event upset chips for radiation effect analysis. The test structures contained in these chips are discussed along with representative test results.

Buehler, M. G.↗

Thermal Design of the Micrometeoroid Satellite S-55

The thermal design of the micrometeoroid satellite S-55 involves both experimental and analytical approaches in selecting materials and coatings. A cutaway drawing of the S-55 satellite is shown. The purpose of which is to obtain scientific and engineering design data on the frequency and penetration hazard of micrometeoroids at altitudes between about 250 nautical miles and 700 nautical miles. The passive method of thermal control used involves the selection of materials and coatings that give the desired ratio of absorptivity to emissivity alpha/epsilon for keeping the telemetry temperature within narrow limits and also to prevent overheating of the separate experiments. The selection of a material or coating for this purpose, however, is dictated not only by its absorptivity and emissivity values, but also by its reliability and the constancy of these values under long exposure to the space environment. Several test programs have been conducted in order to evaluate the materials and coatings being considered. Some of these are as follows: (1) Ultraviolet radiation in a vacuum to study discoloration and weight change. (2) Solar radiation in a vacuum to determine maximum equilibrium temperature, discoloration, and weight loss. (3) Thermal cycling and thermal shock to study material integrity (leaking, spalling, melting, etc.). (4) Proton radiation to observe effects on color, crystal structure, and strength. (5) Determination of effects of heat associated with coating application on the leak rate of pressurized parts. (6) Absorptivity and emissivity measurements. The experimental tests outlined and the maximum use of coating methods successfully employed on previous satellites should provide high reliability of the material used for the thermal design of this vehicle. A theoretical analysis was made to determine the values of alpha/epsilon required for different areas in order that the telemetry remain within the desired temperature limits.

Hastings, Earl C., Jr.↗

Analysis of Historical International Space Station Logistical Mass Delivery

Crewed space exploration missions are extremely logistics dependent, as cargo requirements shape numerous program elements such as vehicle and habitat size. Logistics mass is the mass of items like food and clothing that are not a part of the vehicle or habitat, yet are required by the crew to complete the mission. Numerous studies, such as the Human Exploration Research Analog (HERA) and the Human Exploration Spacecraft Testbed for Integration and Advancement (HESTIA) 20-foot chamber analog, have been conceived to research the rates at which crews consume logistics mass. These analogs can simulate many aspects of life in space, including confinement, isolation, limited supplies, and, in certain experiments, the habitat pressure. However, some aspects of space exploration, such as the effects of low gravity and the use of space-based amenities, cannot currently be tested on the ground. In this paper, International Space Station (ISS) manifest data obtained through the National Aeronautics and Space Administration’s (NASA’s) Mission Integration Database Application System (MIDAS) portal is used as a precursor to space-based analogs. The objective of the analysis is determining the breakdown of logistics mass used in space exploration. This identifies potential areas of improvement and highlights the rates at which significant items are supplied, aiding in the weighing of alternative options such as utilizing in space manufacturing for supplies vs. manifesting spares, or cleaning clothing in flight vs. discarding it. Official flight manifests ranging a span of 878 days, just short of the three-year length of a potential human mission to Mars, were analyzed to find the rates at which astronauts consumed various logistics supplies. From this analysis we have found that contrary to our own hypothesis, ‘food’ was not the largest portion of the supplied mass. Instead, ‘Environmental Control and Life Support Systems’ (ECLSS) contributed 34% of the overall supplied mass, followed by ‘Science and Outfitting,’ which contributed 29%. Food totaled less than a quarter (21% of the resupplied mass, while other items of focus in mass reduction efforts such as ‘Hygiene’ (6%), ‘Clothing’ (3%), and ‘Operational Supplies’ (4%) each contributed less than a tenth of the supplied mass. This data suggests that by categorizing and analyzing the data based on an alternative taxonomy and analyzing the full supply manifests rather than handpicked items, we have revealed unexpectedly significant items which had not been previously tracked by exploration logistics efforts. For example, toilet hardware made up 4% of ECLSS mass, and laptop hardware and multi-tools each made up 10% of operational supplies mass. Additionally, the ‘Specialized Clothing’ subcategory containing fire protective equipment, coveralls, and penguin suits made up 15% of the overall clothing mass. By identifying these newly found significant items, we can create more realistic mass estimates for exploration missions and direct mass reduction efforts to new areas, potentially leading to lower future mission masses.

Logistics↗

Integrated Extravehicular Activity Human Research Plan: 2017

Multiple organizations within NASA as well as industry and academia fund and participate in research related to extravehicular activity (EVA). In October 2015, representatives of the EVA Office, the Crew and Thermal Systems Division (CTSD), and the Human Research Program (HRP) at NASA Johnson Space Center agreed on a formal framework to improve multi-year coordination and collaboration in EVA research. At the core of the framework is an Integrated EVA Human Research Plan and a process by which it will be annually reviewed and updated. The over-arching objective of the collaborative framework is to conduct multi-disciplinary cost-effective research that will enable humans to perform EVAs safely, effectively, comfortably, and efficiently, as needed to enable and enhance human space exploration missions. Research activities must be defined, prioritized, planned and executed to comprehensively address the right questions, avoid duplication, leverage other complementary activities where possible, and ultimately provide actionable evidence-based results in time to inform subsequent tests, developments and/or research activities. Representation of all appropriate stakeholders in the definition, prioritization, planning and execution of research activities is essential to accomplishing the over-arching objective. A formal review of the Integrated EVA Human Research Plan will be conducted annually. Coordination with stakeholders outside of the EVA Office, CTSD, and HRP is already in effect on a study-by-study basis; closer coordination on multi-year planning with other EVA stakeholders including academia is being actively pursued. Details of the preliminary Integrated EVA Human Research Plan are presented including description of ongoing and planned research activities in the areas of: physiological and performance capabilities; suit design parameters; EVA human health and performance modeling; EVA tasks and concepts of operations; EVA informatics; human-suit sensors; suit sizing and fit; and EVA injury risk and mitigation. This paper represents the 2017 update to the Integrated EVA Human Research Plan.

Abercromby, Andrew↗

Follow-on cable coupling lightning test, volume 1

A redesigned solid rocket motor test article was subjected to simulated lightning strikes. This test was performed to evaluate the effects of lightning strike to the redesigned motor and Space Transportation System. The purpose of the test was to evaluate the performance of systems tunnel design changes when subjected to the lightning discharges. The goal of the design changes was to reduce lightning induced coupling to cables within the systems tunnel. The test article was subjected to several different amounts and kinds of discharges. Changes in coupling levels detected during the tests are recorded. The dominant mode of coupling appears to be caused by the diffusion of the magnetic fields through the system tunnel covers. The results from bond strap integrity testing showed that 16 of 18 bond straps survived. Design change evaluations showed that coupling reduction ranged from 0 to 36 decibels for each type of cable. The type of cable has less effect on coupling than does strike location and strike levels. Recommendations for design changes are made.

Danforth, Richard↗