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NASA NTRS2013

A Next Generation Air Monitor: Combining Orion and ISS Requirements for a Common Major Constituent Analyzer

The Major Constituent Analyzer (MCA) is a mass spectrometer-based instrument designed to provide critical monitoring of six major atmospheric constituents; nitrogen, oxygen, hydrogen, carbon dioxide, methane, and water vapor on-board the International Space Station. The analyzer has been an integral part of the Environmental Control and Life Support System (ECLSS) since the station went on-line. The Orion Air Monitor (OAM) was derived from the MCA and heavily optimized for reduced mass, lower power, faster water vapor response, and maintenance-free operation. The resulting OAM is approximately the size of the analyzer portion of the MCA, orbital-replacement unit 02 (ORU 02), while incorporating the functions of three other modules: Data Processing and Communication (ORU 01), Verification Gas Assembly (ORU 08), and Low Voltage Power Supply (ORU 04). The overlap in MCA and OAM requirements makes it possible to derive a common Air Monitor design that spans both applications while minimally impacting the weight and power limits imposed by the Multipurpose Crew Vehicle (MPCV). Benefits to ISS include the retirement of ORUs 01, 04, and 08, reducing up-mass and eliminating EEE parts obsolescence issues through the extended ISS mission phases. Benefits to MPCV and future deployed habitats under the Constellation program include greater interchangeability across ECLSS subsystems. This paper discusses the results of the requirements development study, where a superset of ISS and Orion air monitoring requirements were distilled; evaluated against increases in OAM functionality, mass, and power; and traded-off where possible using simple operating mode modifications. A system architecture and preliminary design addressing the common requirements will be presented.

Burchfield, David E.↗

NASA NTRS2013

Effects of the Orion Launch Abort Vehicle Plumes on Aerodynamics and Controllability

Characterization of the launch abort system of the Multi-purpose Crew Vehicle (MPCV) for control design and accurate simulation has provided a significant challenge to aerodynamicists and design engineers. The design space of the launch abort vehicle (LAV) includes operational altitudes from ground level to approximately 300,000 feet, Mach numbers from 0-9, and peak dynamic pressure near 1300psf during transonic flight. Further complicating the characterization of the aerodynamics and the resultant vehicle controllability is the interaction of the vehicle flowfield with the plumes of the two solid propellant motors that provide attitude control and the main propulsive impulse for the LAV. These interactions are a function of flight parameters such as Mach number, altitude, dynamic pressure, vehicle attitude, as well as parameters relating to the operation of the motors themselves - either as a function of time for the AM, or as a result of the flight control system requests for control torque from the ACM. This paper discusses the computational aerodynamic modeling of the aerodynamic interaction caused by main abort motor and the attitude control motor of the MPCV LAV, showing the effects of these interactions on vehicle controllability.

Vicker, Darby↗

NASA NTRS2013

Descent and Landing Triggers for the Orion Multi-Purpose Crew Vehicle Exploration Flight Test-1

The Orion Multi-Purpose Crew Vehicle (MPCV) will perform a flight test known as Exploration Flight Test-1 (EFT-1) currently scheduled for 2014. One of the primary functions of this test is to exercise all of the important Guidance, Navigation, Control (GN&C), and Propulsion systems, along with the flight software for future flights. The Descent and Landing segment of the flight is governed by the requirements levied on the GN&C system by the Landing and Recovery System (LRS). The LRS is a complex system of parachutes and flight control modes that ensure that the Orion MPCV safely lands at its designated target in the Pacific Ocean. The Descent and Landing segment begins with the jettisoning of the Forward Bay Cover and concludes with sensing touchdown. This paper discusses the requirements, design, testing, analysis and performance of the current EFT-1 Descent and Landing Triggers flight software.

Bihari, Brian D.↗

NASA NTRS2013

Tuning and Robustness Analysis for the Orion Absolute Navigation System

The Orion Multi-Purpose Crew Vehicle (MPCV) is currently under development as NASA's next-generation spacecraft for exploration missions beyond Low Earth Orbit. The MPCV is set to perform an orbital test flight, termed Exploration Flight Test 1 (EFT-1), some time in late 2014. The navigation system for the Orion spacecraft is being designed in a Multi-Organizational Design Environment (MODE) team including contractor and NASA personnel. The system uses an Extended Kalman Filter to process measurements and determine the state. The design of the navigation system has undergone several iterations and modifications since its inception, and continues as a work-in-progress. This paper seeks to show the efforts made to-date in tuning the filter for the EFT-1 mission and instilling appropriate robustness into the system to meet the requirements of manned space ight. Filter performance is affected by many factors: data rates, sensor measurement errors, tuning, and others. This paper focuses mainly on the error characterization and tuning portion. Traditional efforts at tuning a navigation filter have centered around the observation/measurement noise and Gaussian process noise of the Extended Kalman Filter. While the Orion MODE team must certainly address those factors, the team is also looking at residual edit thresholds and measurement underweighting as tuning tools. Tuning analysis is presented with open loop Monte-Carlo simulation results showing statistical errors bounded by the 3-sigma filter uncertainty covariance. The Orion filter design uses 24 Exponentially Correlated Random Variable (ECRV) parameters to estimate the accel/gyro misalignment and nonorthogonality. By design, the time constant and noise terms of these ECRV parameters were set to manufacturer specifications and not used as tuning parameters. They are included in the filter as a more analytically correct method of modeling uncertainties than ad-hoc tuning of the process noise. Tuning is explored for the powered-flight ascent phase, where measurements are scarce and unmodelled vehicle accelerations dominate. On orbit, there are important trade-off cases between process and measurement noise. On entry, there are considerations about trading performance accuracy for robustness. Process Noise is divided into powered flight and coasting ight and can be adjusted for each phase and mode of the Orion EFT-1 mission. Measurement noise is used for the integrated velocity measurements during pad alignment. It is also used for Global Positioning System (GPS) pseudorange and delta- range measurements during the rest of the flight. The robustness effort has been focused on maintaining filter convergence and performance in the presence of unmodeled error sources. These include unmodeled forces on the vehicle and uncorrected errors on the sensor measurements. Orion uses a single-frequency, non-keyed GPS receiver, so the effects due to signal distortion in Earth's ionosphere and troposphere are present in the raw measurements. Results are presented showing the efforts to compensate for these errors as well as characterize the residual effect for measurement noise tuning. Another robustness tool in use is tuning the residual edit thresholds. The trade-off between noise tuning and edit thresholds is explored in the context of robustness to errors in dynamics models and sensor measurements. Measurement underweighting is also presented as a method of additional robustness when processing highly accurate measurements in the presence of large filter uncertainties.

Holt, Greg N.↗

NASA NTRS2013

Tuning and Robustness Analysis for the Orion Absolute Navigation System

Holt, Greg N.↗

NASA NTRS2014

Asteroid Redirect Crewed Mission Space Suit and EVA System Architecture Trade Study

The Asteroid Redirect Crewed Mission (ARCM) requires a Launch/Entry/Abort (LEA) suit capability and short duration Extra Vehicular Activity (EVA) capability for Orion. The EVAs will involve a two-person crew for approximately four hours. Currently, two EVAs are planned with one contingency EVA in reserve. Providing this EVA capability is very challenging due to system level constraints and a new and unknown environment. The goal of the EVA architecture for ARCM is one that builds upon previously developed technologies and lessons learned, and that accomplishes the ARCM mission while providing a stepping stone to future missions and destinations. The primary system level constraints are to 1) minimize system mass and volume and 2) minimize the interfacing impacts to the baseline Orion design. In order to minimize the interfacing impacts and to not perturb the baseline Orion schedule, the concept of adding "kits" to the baseline system is proposed. These kits consist of: an EVA kit (converts LEA suit to EVA suit), EVA Servicing and Recharge Kit (provides suit consumables), the EVA Tools, Translation Aids & Sample Container Kit (the tools and mobility aids to complete the tasks), the EVA Communications Kit (interface between the EVA radio and the MPCV), and the Cabin Repress Kit (represses the MPCV between EVAs). This paper will focus on the trade space, analysis, and testing regarding the space suit (pressure garment and life support system). Historical approaches and lessons learned from all past EVA operations were researched. Previous and current, successfully operated EVA hardware and high technology readiness level (TRL) hardware were evaluated, and a trade study was conducted for all possible pressure garment and life support options. Testing and analysis was conducted and a recommended EVA system architecture was proposed. Pressure garment options that were considered for this mission include the currently in-use ISS EVA Mobility Unit (EMU), all variations of the Advanced Crew Escape Suit (ACES), and the Exploration Z-suit. For this mission, the pressure garment that was selected is the Modified ACES (MACES) with EVA enhancements. Life support options that were considered included short closed-loop umbilicals, long open-loop umbilicals, the currently in-use ISS EMU Portable Life Support System (PLSS), and the currently in development Exploration PLSS. For this mission, the life support option that was selected is the Exploration PLSS. The greatest risk in the proposed architecture is viewed to be the comfort and mobility of the baseline MACES and the delicate balance between adding more mobility features while not compromising landing safety. Feasibility testing was accomplished in low fidelity analogs and in the JSC Neutral Buoyancy Laboratory (NBL) to validate the concept before a final recommendation on the architecture was made. The proposed architecture was found to meet the mission constraints, but much more work is required to determine the details of the required suit upgrades, the integration with the PLSS, and the rest of the tools and equipment required to accomplish the mission. This work and further definition of the remaining kits will be conducted in government fiscal year 14.

Blanco, Raul A.↗

NASA NTRS2014

SLS Trade Study 0058: Day of Launch (DOL) Wind Biasing

SLS heritage hardware and legacy designs have shown load exceedances at several locations during Design Analysis Cycles (DAC): MPCV Z bending moments; ICPS Electro-Mechanical Actuator (EMA) loads; Core Stage loads just downstream of Booster forward interface. SLS Buffet Loads Mitigation Task Team (BLMTT) tasked to study issue. Identified low frequency buffet load responses are a function of the vehicle's total angle of attack (AlphaTotal). SLS DOL Wind Biasing Trade team to analyze DOL wind biasing methods to limit maximum AlphaTotal in the M0.8 - 2.0 altitude region for EM-1 and EM-2 missions through investigating: Trajectory design process; Wind wavelength filtering options; Launch availability; DOL process to achieve shorter processing/uplink timeline. Trade Team consisted of personnel supporting SLS, MPCV, GSDO programs.

Decker, Ryan K.↗

NASA NTRS2014

Development Testing and Subsequent Failure Investigation of a Spring Strut Mechanism

Commodities are transferred between the Multi-Purpose Crew Vehicle (MPCV) crew module (CM) and service module (SM) via an external umbilical that is driven apart with spring-loaded struts after the structural connection is severed. The spring struts must operate correctly for the modules to separate safely. There was no vibration testing of strut development units scoped in the MPCV Program Plan; therefore, any design problems discovered as a result of vibration testing would not have been found until the component qualification. The NASA Engineering and Safety Center (NESC) and Lockheed Martin (LM) performed random vibration testing on a single spring strut development unit to assess its ability to withstand qualification level random vibration environments. Failure of the strut while exposed to random vibration resulted in a follow-on failure investigation, design changes, and additional development tests. This paper focuses on the results of the failure investigations including identified lessons learned and best practices to aid in future design iterations of the spring strut and to help other mechanism developers avoid similar pitfalls.

Dervan, Jared↗

NASA NTRS2014

Use of DES Modeling for Determining Launch Availability for SLS

The National Aeronautics and Space Administration (NASA) is developing new capabilities for human and scientific exploration beyond Earth's orbit. This effort includes the Space Shuttle derived Space Launch System (SLS), the Multi-Purpose Crew Vehicle (MPCV) "Orion", and the Ground Systems Development and Operations (GSDO). There are several requirements and Technical Performance Measures (TPMs) that have been levied by the Exploration Systems Development (ESD) upon the SLS, MPCV, and GSDO Programs including an integrated Launch Availability (LA) TPM. The LA TPM is used to drive into the SLS, Orion and GSDO designs a high confidence of successfully launching exploration missions that have narrow Earth departure windows. The LA TPM takes into consideration the reliability of the overall system (SLS, Orion and GSDO), natural environments, likelihood of a failure, and the time required to recover from an anomaly. A challenge with the LA TPM is the interrelationships between SLS, Orion, GSDO and the natural environments during launch countdown and launch delays that makes it impossible to develop an analytical solution for calculating the integrated launch probability. This paper provides an overview of how Discrete Event Simulation (DES) modeling was used to develop the LA TPM, how it was allocated down to the individual programs, and how the LA analysis is being used to inform and drive the SLS, Orion, and GSDO designs to ensure adequate launch availability for future human exploration.

Watson, Mike↗

NASA NTRS2014

Analyzing the Impacts of Natural Environments on Launch and Landing Availability for NASA's Exploration Systems Development Programs

The National Aeronautics and Space Administration (NASA) is developing new capabilities for human and scientific exploration beyond Earth orbit. Natural environments information is an important asset for NASA's development of the next generation space transportation system as part of the Exploration Systems Development (ESD) Programs, which includes the Space Launch System (SLS) and Multi-Purpose Crew Vehicle (MPCV) Programs. Natural terrestrial environment conditions - such as wind, lightning and sea states - can affect vehicle safety and performance during multiple mission phases ranging from pre-launch ground processing to landing and recovery operations, including all potential abort scenarios. Space vehicles are particularly sensitive to these environments during the launch/ascent and the entry/landing phases of mission operations. The Marshall Space Flight Center (MSFC) Natural Environments Branch provides engineering design support for NASA space vehicle projects and programs by providing design engineers and mission planners with natural environments definitions as well as performing custom analyses to help characterize the impacts the natural environment may have on vehicle performance. One such analysis involves assessing the impact of natural environments to operational availability. Climatological time series of operational surface weather observations are used to calculate probabilities of meeting/exceeding various sets of hypothetical vehicle-specific parametric constraint thresholds. Outputs are tabulated by month and hour of day to show both seasonal and diurnal variation. This paper will discuss how climate analyses are performed by the MSFC Natural Environments Branch to support the ESD Launch Availability (LA) Technical Performance Measure (TPM), the SLS Launch Availability due to Natural Environments TPM, and several MPCV (Orion) launch and landing availability analyses - including the 2014 Orion Exploration Flight Test 1 (EFT-1) mission.

Altino, Karen M.↗

NASA NTRS2014

Visualization of Capsule Reentry Vehicle Heat Shield Ablation Using Naphthalene PLIF

The Orion Multi-Purpose Crew Vehicle (MPCV) will use an ablative heat shield and improved understanding of the ablation process would be beneficial for design purposes. Given that ablation is a multi-physics process involving heat and mass transfer, codes aiming to predict heat shield ablation are in need of experimental data pertaining to the turbulent transport of ablation products for validation. At The University of Texas at Austin, a technique is being developed that uses planar laser-induced fluorescence (PLIF) of a low-temperature sublimating ablator (naphthalene) to visualize the transport of ablation products in a supersonic flow. Since ablation at reentry temperatures can be difficult to recreate in a laboratory setting it is desirable to create a limited physics problem and simulate the ablation process at relatively low temperature conditions using naphthalene. A scaled Orion MPCV model with a solid naphthalene heat shield has been tested in a Mach 5 wind tunnel at various angles of attack in the current work. PLIF imaging reveals the distribution of the ablation products as they are transported into the heat-shield boundary layer and over the capsule shoulders into the separated shear layer and backshell recirculation region. Visualizations of the capsule shear layer using both naphthalene PLIF and Schlieren imaging compared favorably. High concentrations of naphthalene in the capsule separated flow region, intermittent turbulent structures on the heat shield surface, and interesting details of the capsule shear layer structure were observed using the naphthalene PLIF technique. The capsule shear layer was also shown to generally appear to be more turbulent at lower angles of attack. Furthermore, the PLIF signal increased steadily over the course of a run indicating that during a wind tunnel run the model heated up and the rate of naphthalene ablation increased. The shear layer showed increasing signs of turbulence over the course of a wind tunnel run as well, likely because of the combination of increased surface roughness and surface blowing rate. PLIF imaging also detected regions with a relatively low concentration of naphthalene in the capsule backshell recirculation region that are most likely the result of cross-flow-induced vortices on the capsule afterbody.

Combs, Christopher S.↗

NASA NTRS2012

NASA and ESA Partnership on the Multi-Purpose Crew Vehicle Service Module

(1) ESA decided in its Council Meeting in March 2011 to partially offset the European ISS obligations after 2015 with different means than ATVs; (2) The envisioned approach is based on a barter element(s) that would generate cost avoidance on the NASA side; (3) NASA and ESA considered a number of Barter options, NASA concluded that the provision by ESA of the Service Module for the NASA Multi-Purpose Crew Vehicle (MPCV) was the barter with the most interest;. (4) A joint ESA - NASA working group was established in May 2011 to assess the feasibility of Europe developing this Module based on ATV heritage; (5)The working group was supported by European and US industry namely Astrium, TAS-I and Lockheed-Martin; and (6) The project is currently in phase B1 with the objective to prepare a technical and programmatic proposal for an ESA MPCV-SM development. This proposal will be one element of the package that ESA plans submit to go forward for approval by European Ministers in November 2012.

Schubert, Kathleen E.↗

NASA NTRS2015

Customer Avionics Interface Development and Analysis (CAIDA) Lab DEWESoft Display Creation

The Customer Avionics Interface Development and Analysis (CAIDA) Lab supports the testing of the Launch Control System (LCS), NASA's command and control system for the Space Launch System (SLS), Orion Multi-Purpose Crew Vehicle (MPCV), and ground support equipment. The objectives of the year-long internship were to support day-to-day operations of the CAIDA Lab, create prelaunch and tracking displays for Orion's Exploration Flight Test 1 (EFT-1), and create a program to automate the creation of displays for SLS and MPCV to be used by CAIDA and the Record and Playback Subsystem (RPS).

DEWESoft↗

NASA NTRS2015

A Year of Progress: NASA's Space Launch System Approaches Critical Design Review

NASA's Space Launch System (SLS) made significant progress on the manufacturing floor and on the test stand in 2014 and positioned itself for a successful Critical Design Review in mid-2015. SLS, the world's only exploration-class heavy lift rocket, has the capability to dramatically increase the mass and volume of human and robotic exploration. Additionally, it will decrease overall mission risk, increase safety, and simplify ground and mission operations - all significant considerations for crewed missions and unique high-value national payloads. Development now is focused on configuration with 70 metric tons (t) of payload to low Earth orbit (LEO), more than double the payload of the retired Space Shuttle program or current operational vehicles. This "Block 1" design will launch NASA's Orion Multi-Purpose Crew Vehicle (MPCV) on an uncrewed flight beyond the Moon and back and the first crewed flight around the Moon. The current design has a direct evolutionary path to a vehicle with a 130t lift capability that offers even more flexibility to reduce planetary trip times, simplify payload design cycles, and provide new capabilities such as planetary sample returns. Every major element of SLS has successfully completed its Critical Design Review and now has hardware in production or testing. In fact, the SLS MPCV-to-Stage-Adapter (MSA) flew successfully on the Exploration Flight Test (EFT) 1 launch of a Delta IV and Orion spacecraft in December 2014. The SLS Program is currently working toward vehicle Critical Design Review in mid-2015. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Askins, Bruce↗

NASA NTRS2016

Orion Exploration Flight Test Reaction Control System Jet Interaction Heating Environment from Flight Data

The Orion Multi-Purpose Crew Vehicle (MPCV) Reaction Control System (RCS) is critical to guide the vehicle along the desired trajectory during re-‐entry. However, this system has a significant impact on the convective heating environment to the spacecraft. Heating augmentation from the jet interaction (JI) drives thermal protection system (TPS) material selection and thickness requirements for the spacecraft. This paper describes the heating environment from the RCS on the afterbody of the Orion MPCV during Orion's first flight test, Exploration Flight Test 1 (EFT-1). These jet plumes interact with the wake of the crew capsule and cause an increase in the convective heating environment. Not only is there widespread influence from the jet banks, there may also be very localized effects. The firing history during EFT-1 will be summarized to assess which jet bank interaction was measured during flight. Heating augmentation factors derived from the reconstructed flight data will be presented. Furthermore, flight instrumentation across the afterbody provides the highest spatial resolution of the region of influence of the individual jet banks of any spacecraft yet flown. This distribution of heating augmentation across the afterbody will be derived from the flight data. Additionally, trends with possible correlating parameters will be investigated to assist future designs and ground testing programs. Finally, the challenges of measuring JI, applying this data to future flights and lessons learned will be discussed.

White, Molly E.↗

NASA NTRS2016

Innovative Approach for Developing Spacecraft Interior Acoustic Requirement Allocation

The Orion Multi-Purpose Crew Vehicle (MPCV) is an American spacecraft for carrying four astronauts during deep space missions. This paper describes an innovative application of Power Injection Method (PIM) for allocating Orion cabin continuous noise Sound Pressure Level (SPL) limits to the sound power level (PWL) limits of major noise sources in the Environmental Control and Life Support System (ECLSS) during all mission phases. PIM is simulated using both Statistical Energy Analysis (SEA) and Hybrid Statistical Energy Analysis-Finite Element (SEA-FE) models of the Orion MPCV to obtain the transfer matrix from the PWL of the noise sources to the acoustic energies of the receivers, i.e., the cavities associated with the cabin habitable volume. The goal of the allocation strategy is to control the total energy of cabin habitable volume for maintaining the required SPL limits. Simulations are used to demonstrate that applying the allocated PWLs to the noise sources in the models indeed reproduces the SPL limits in the habitable volume. The effects of Noise Control Treatment (NCT) on allocated noise source PWLs are investigated. The measurement of source PWLs of involved fan and pump development units are also discussed as it is related to some case-specific details of the allocation strategy discussed here.

Chu, S. Reynold↗

NASA NTRS2016

NASA's Space Launch System Marks Critical Design Review

With completion of its Critical Design Review (CDR) in 2015, NASA is deep into the manufacturing and testing phases of its new Space Launch System (SLS) for beyond-Earth exploration. This CDR was the first in almost 40 years for a NASA human launch vehicle and marked another successful milestone on the road to the launch of a new era of deep space exploration. The review marked the 90-percent design-complete, a final look at the design and development plan of the integrated vehicle before full-scale fabrications begins and the prelude to the next milestone, design certification. Specifically, the review looked at the first of three increasingly capable configurations planned for SLS. This "Block I" design will stand 98.2 meters (m) (322 feet) tall and provide 39.1 million Newtons (8.8 million pounds) of thrust at liftoff to lift a payload of approximately 70 metric tons (154,000 pounds). This payload is more than double that of the retired space shuttle program or other current launch vehicles. It dramatically increases the mass and volume of human and robotic exploration. Additionally, it will decrease overall mission risk, increase safety, and simplify ground and mission operations - all significant considerations for crewed missions and unique, high-value national payloads. The Block 1 SLS will launch NASA's Orion Multi-Purpose Crew Vehicle (MPCV) on an uncrewed flight beyond the moon and back and the first crewed flight around the moon. The current design has a direct evolutionary path to a vehicle with a 130t lift capability that offers even more flexibility to reduce planetary trip times, simplify payload design cycles, and provide new capabilities such as planetary sample returns. Every major element of SLS has hardware in production or testing, including flight hardware for the Exploration 1 (EM-1) test flight. In fact, the SLS MPCV-to-Stage-Adapter (MSA) flew successfully on the Exploration Flight Test (EFT) 1 launch of a Delta IV and Orion spacecraft in December 2014. This paper will discuss these and other technical and programmatic successes and challenges over the past year and provide a preview of work ahead before the first flight of this new capability.

Singer, Chris↗

NASA NTRS2016

Innovative Approach for Developing Spacecraft Interior Acoustic Requirement Allocation

Chu, S. Reynold↗