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Design and Development Requirements for Mechanisms

This NASA Technical Standard is published by the National Aeronautics and Space Administration (NASA) to provide uniform engineering and technical requirements for processes, procedures, practices, and methods endorsed as standard for NASA programs and projects, including requirements for selection, application, and design criteria of an item. This Standard is approved for use by NASA Headquarters and NASA Centers, including Component Facilities and Technical and Service Support Centers; applicable technical requirements may be cited in contract, program, and other Agency documents. This language applies to the Jet Propulsion Laboratory (a Federally Funded Research and Development Center), other contractors, recipients of grants, cooperative agreements, or other agreements only to the extent specified or referenced in the applicable contracts, grants, or agreements. This Standard establishes uniform design, development, and verification requirements for mechanisms and mechanism components whose correct operation is required for safety or mission success.

Mechanism↗

Mars Exploration Rover Entry, Descent, and Landing: A Thermal Perspective

Perhaps the most challenging mission phase for the Mars Exploration Rovers was the Entry, Descent, and Landing (EDL). During this phase, the entry vehicle attached to its cruise stage was transformed into a stowed tetrahedral Lander that was surrounded by inflated airbags through a series of complex events. There was only one opportunity to successfully execute an automated command sequence without any possible ground intervention. The success of EDL was reliant upon the system thermal design: 1) to thermally condition EDL hardware from cruise storage temperatures to operating temperature ranges; 2) to maintain the Rover electronics within operating temperature ranges without the benefit of the cruise single phase cooling loop, which had been evacuated in preparation for EDL; and 3) to maintain the cruise stage propulsion components for the critical turn to entry attitude. Since the EDL architecture was inherited from Mars Pathfinder (MPF), the initial EDL thermal design would be inherited from MPF. However, hardware and implementation differences from MPF ultimately changed the MPF inheritance approach for the EDL thermal design. With the lack of full inheritance, the verification and validation of the EDL thermal design took on increased significance. This paper will summarize the verification and validation approach for the EDL thermal design along with applicable system level thermal testing results as well as appropriate thermal analyses. In addition, the lessons learned during the system-level testing will be discussed. Finally, the in-flight EDL experiences of both MER-A and -B missions (Spirit and Opportunity, respectively) will be presented, demonstrated how lessons learned from Spirit were applied to Opportunity.

thermal↗

James Webb Space Telescope Integrated Science Instrument Module Thermal Vacuum Thermal Balance Test Campaign at NASA's Goddard Space Flight Center

The James Webb Space Telescope is a large infrared telescope with a 6.5-meter primary mirror, designed as a successor to the Hubble Space Telescope when launched in 2018. Three of the four science instruments contained within the Integrated Science Instrument Module (ISIM) are passively cooled to their operational temperature range of 36K to 40K with radiators, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. Thermal-vacuum testing of the flight science instruments at the ISIM element level has taken place in three separate highly challenging and extremely complex thermal tests within a gaseous helium-cooled shroud inside Goddard Space Flight Centers Space Environment Simulator. Special data acquisition software was developed for these tests to monitor over 1700 flight and test sensor measurements, track over 50 gradients, component rates, and temperature limits in real time against defined constraints and limitations, and guide the complex transition from ambient to final cryogenic temperatures and back. This extremely flexible system has proven highly successful in safeguarding the nearly $2B science payload during the 3.5-month-long thermal tests. Heat flow measurement instrumentation, or Q-meters, were also specially developed for these tests. These devices provide thermal boundaries o the flight hardware while measuring instrument heat loads up to 600 mW with an estimated uncertainty of 2 mW in test, enabling accurate thermal model correlation, hardware design validation, and workmanship verification. The high accuracy heat load measurements provided first evidence of a potentially serious hardware design issue that was subsequently corrected. This paper provides an overview of the ISIM-level thermal-vacuum tests and thermal objectives; explains the thermal test configuration and thermal balances; describes special measurement instrumentation and monitoring and control software; presents key test thermal results; lists problems encountered during testing and lessons learned.

JWST ISIM Thermal↗

Test verification of LOX/RP-1 high-pressure fuel/oxidizer-rich preburner designs

Two fuel-rich and two oxidizer-rich preburner injectors are tested with LOX/RP-1 in an investigation of performance, stability and gas temperature uniformity over a chamber pressure range from 1292 to 2540 psia. Fuel-rich mixture ratios range from 0.238 to 0.367 and oxidizer-rich mixture ratios range from 27 to 48, and carbon deposition data are collected by measuring the pressure drop across a turbine simulator flow device. The oxidizer-rich testing demonstrates the feasibility of oxidizer-rich preburners, indicating equilibrium combustion as predicted, and the measured fuel-rich gas composition and C-asterisk performance are in excellent agreement with kinetic model predictions indicating kinetically-limited combustion.

Lawver, B. R.↗

Analysis, Verification, and Application of Equations and Procedures for Design of Exhaust-pipe Shrouds

Investigations were made to develop a simplified method for designing exhaust-pipe shrouds to provide desired or maximum cooling of exhaust installations. Analysis of heat exchange and pressure drop of an adequate exhaust-pipe shroud system requires equations for predicting design temperatures and pressure drop on cooling air side of system. Present experiments derive such equations for usual straight annular exhaust-pipe shroud systems for both parallel flow and counter flow. Equations and methods presented are believed to be applicable under certain conditions to the design of shrouds for tail pipes of jet engines.

HEAT EXCHANGERS, SHROUDED↗

An overview of key technology thrusts at Bell Helicopter Textron

Insight is provided into several key technologies at Bell. Specific topics include the results of ongoing research and development in advanced rotors, methodology development, and new configurations. The discussion on advanced rotors highlight developments on the composite, bearingless rotor, including the development and testing of full scale flight hardware as well as some of the design support analyses and verification testing. The discussion on methodology development concentrates on analytical development in aeromechanics, including correlation studies and design application. New configurations, presents the results of some advanced configuration studies including hardware development.

Harse, James H.↗

Innovative Research Program: Supershields for Gamma-Ray Astronomy

The supershield project evaluated the importance of novel shield configurations for suppressing neutron induced background in new classes of gamma-ray detectors such as CZT. The basic concept was to use a two-part shield. The outer shield material heavily moderates the incoming neutron spectrum. This moderated neutron beam is then more easily absorbed by the inner material, which is an efficient neutron absorber. This approach is, in principle, more efficient than that in previous attempts to make neutron shields. These previous attempts involved biatomic, monlithic shields (eg. LiH) in which the shield consisted of a single material but with two types of atoms - one for moderating and one for absorbing. The problem with this type of monolithic shield is that moderating neutrons, without the efficient absorption of them, leads to the leakage into the detector of neutrons with a low energy component (approx. 10-100 KeV). These energy neutrons are particularly problematic for many types of detectors. The project was roughly divided into phases. In the first phase we attempted to carefully define the neutron source function incident on any space instrument. This is essential since the design of any shield depends on the shape of the incident neutron spectrum. We found that approximations commonly used in gamma-ray astronomy for photon background is inadequate. In addition, we found that secondary neutrons produced in any passive shield, and dominated by inelastic neutron scattering, are far more important than background due to neutron activation. The second phase of our work involved design of supershield geometries (one and three dimensional) in order to compare different shield configurations and materials for their effectiveness as neutron shields. Moreover we wanted to compare these supershields with previous neutron shields to confirm the performance differences between the supershield (two material) and monolithic (one material) designs and to understand the physics origins of these differences more clearly. The third phase of the supershield program involved the benchmarking of the supershield designs through direct experimental verification. This required fabricating various supershields and exposing them to beams of neutrons to directly characterize their performance. With explicit verification that our modeling procedures can be used with confidence, we are now in a position to design shields for realistic space geometries. Using the supershield modeling capacity developed as part of this program we are attempting to evaluate their utility for a specific proposed mission--the Energetic X-ray Imaging Survey Telescope (EXIST). It is anticipated that this experiment, which is limited by internal background at high energies, might benefit from a neutron shield.

Hailey, Charles J.↗

Space station System Engineering and Integration (SE and I). Volume 2: Study results

A summary of significant study results that are products of the Phase B conceptual design task are contained. Major elements are addressed. Study results applicable to each major element or area of design are summarized and included where appropriate. Areas addressed include: system engineering and integration; customer accommodations; test and program verification; product assurance; conceptual design; operations and planning; technical and management information system (TMIS); and advanced development.

Source record↗

Identification and verification of termination conditions in fine motion in presence of sensor errors and geometric uncertainties

Results are reported from a search for reasonable constraints under which an automatic uncertainty-handling strategy (for robot part-mating tasks) is guaranteed to succeed. The concept of contact formations is introduced to describe contacts among parts in a system, aiming at reducing the dimensionality of assembly verification. Also described is a technique for identifying contact formations in spite of errors in sensing and geometric uncertainties. It is impossible to verify termination conditions in general. Design constraints for which verification can be guaranteed are formulated and shown to be reasonable in the sense that they do not impose unrealistic conditions on typical designs. Results of implementation on a robot system consisting of a PUMA robot with RTI force/torque sensors support the theoretical derivations and show empirically that good results can still be obtained when the theoretical constraints are relaxed somewhat.

Desai, Rajiv S.↗

Requirements, Verification, and Compliance (RVC) Database Tool

This paper describes the development, design, and implementation of the Requirements, Verification, and Compliance (RVC) database used on the International Space Welding Experiment (ISWE) project managed at Marshall Space Flight Center. The RVC is a systems engineer's tool for automating and managing the following information: requirements; requirements traceability; verification requirements; verification planning; verification success criteria; and compliance status. This information normally contained within documents (e.g. specifications, plans) is contained in an electronic database that allows the project team members to access, query, and status the requirements, verification, and compliance information from their individual desktop computers. Using commercial-off-the-shelf (COTS) database software that contains networking capabilities, the RVC was developed not only with cost savings in mind but primarily for the purpose of providing a more efficient and effective automated method of maintaining and distributing the systems engineering information. In addition, the RVC approach provides the systems engineer the capability to develop and tailor various reports containing the requirements, verification, and compliance information that meets the needs of the project team members. The automated approach of the RVC for capturing and distributing the information improves the productivity of the systems engineer by allowing that person to concentrate more on the job of developing good requirements and verification programs and not on the effort of being a "document developer".

Rainwater, Neil E., II↗

Full-Scale Wind-Tunnel Investigation of Wing-Cooling Ducts Effects of Propeller Slipstream, Special Report

The safety of remotely operated vehicles depends on the correctness of the distributed protocol that facilitates the communication between the vehicle and the operator. A failure in this communication can result in catastrophic loss of the vehicle. To complicate matters, the communication system may be required to satisfy several, possibly conflicting, requirements. The design of protocols is typically an informal process based on successive iterations of a prototype implementation. Yet distributed protocols are notoriously difficult to get correct using such informal techniques. We present a formal specification of the design of a distributed protocol intended for use in a remotely operated vehicle, which is built from the composition of several simpler protocols. We demonstrate proof strategies that allow us to prove properties of each component protocol individually while ensuring that the property is preserved in the composition forming the entire system. Given that designs are likely to evolve as additional requirements emerge, we show how we have automated most of the repetitive proof steps to enable verification of rapidly changing designs.

Nickle, F. R.↗

A comprehensive method for preliminary design optimization of axial gas turbine stages. II - Code verification

The present effort represents an extension of previous work wherein a calculation model for performing rapid pitchline optimization of axial gas turbine geometry, including blade profiles, is developed. The model requires no specification of geometric constraints. Output includes aerodynamic performance (adiabatic efficiency), hub-tip flow-path geometry, blade chords, and estimates of blade shape. Presented herein is a verification of the aerodynamic performance portion of the model, whereby detailed turbine test-rig data, including rig geometry, is input to the model to determine whether tested performance can be predicted. An array of seven (7) NASA single-stage axial gas turbine configurations is investigated, ranging in size from 0.6 kg/s to 63.8 kg/s mass flow and in specific work output from 153 J/g to 558 J/g at design (hot) conditions; stage loading factor ranges from 1.15 to 4.66.

Jenkins, R. M.↗

Simulation of Attitude and Trajectory Dynamics and Control of Multiple Spacecraft

Agora software is a simulation of spacecraft attitude and orbit dynamics. It supports spacecraft models composed of multiple rigid bodies or flexible structural models. Agora simulates multiple spacecraft simultaneously, supporting rendezvous, proximity operations, and precision formation flying studies. The Agora environment includes ephemerides for all planets and major moons in the solar system, supporting design studies for deep space as well as geocentric missions. The environment also contains standard models for gravity, atmospheric density, and magnetic fields. Disturbance force and torque models include aerodynamic, gravity-gradient, solar radiation pressure, and third-body gravitation. In addition to the dynamic and environmental models, Agora supports geometrical visualization through an OpenGL interface. Prototype models are provided for common sensors, actuators, and control laws. A clean interface accommodates linking in actual flight code in place of the prototype control laws. The same simulation may be used for rapid feasibility studies, and then used for flight software validation as the design matures. Agora is open-source and portable across computing platforms, making it customizable and extensible. It is written to support the entire GNC (guidance, navigation, and control) design cycle, from rapid prototyping and design analysis, to high-fidelity flight code verification. As a top-down design, Agora is intended to accommodate a large range of missions, anywhere in the solar system. Both two-body and three-body flight regimes are supported, as well as seamless transition between them. Multiple spacecraft may be simultaneously simulated, enabling simulation of rendezvous scenarios, as well as formation flying. Built-in reference frames and orbit perturbation dynamics provide accurate modeling of precision formation control.

Stoneking, Eric T.↗