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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS2018

Hybridized Agile Software Development of Flight Control Team Tools for International Space Station's Payload Operations Integration Center

Ground systems operations at the National Aeronautics and Space Administration's (NASA) Payload Operations and Integration Center (POIC) at Marshall Space Flight Center (MSFC) recently increased via a High Operations Tempo (HOT) initiative, in order to support more science activities with a fourth crew member on the International Space Station (ISS). The Flight Control Team's (FCT) need to support this increasing pace of payload science operations was the impetus for creating a series of new tools. While their need was clear, the full scope and user experience for each tool was not as well-understood, thus establishing a fixed set of initial requirements was not feasible. A hybridized Agile Software Development (ASD) paradigm was created to take advantage of this uncertainty, plan for it, permit the exploration of novel concepts, and also facilitate a rapid and flexible response to inevitably changing requirements. The POIC's hybridized ASD approach places preeminent focus on providing customer value through the delivery of high quality, customer-focused solutions in short timeframes. This has been successfully achieved through creating unprecedented modes of cooperation and collaboration between operations and software development teams, frequent user evaluations of the software with well-defined feedback mechanisms, increased human factors involvement, and a dedication to successful outcomes by the whole of the POIC. Since space science operations and software development are not typically so closely linked, this paper discusses an approach that offers an optimal way to provide an increased return on investment and a faster time-to-completion than traditional software development paradigms, while aiming at delivering high quality products and customer-driven value.

Albers, Cerese M.↗
NASA NTRS2019

Heat Analysis Manager (HAM), a Thermal Desktop API Based Heat Map Generation Software

Thermal engineers often create custom heat maps to analyze their thermal model. However, generating a heat map is difficult because thermal simulation only readily provide attributes of simulated nodes such as temperature, capacitance, heat generation, and a network of conductances. Heat flow values are a derived quantity from the nodal attributes, and the data processing and management of heat flow between nodes quickly become difficult for large models. Deriving a network of heat flow values requires vast amount of calculations and data handling, heat map generation process generally suffers from processing speed, loss of accuracy, and/or presentation of data in a useful format. Heat Analysis Manager (HAM) is a Thermal Desktop (TD) based free multi-purpose tool developed to aid thermal engineers in analyzing their thermal model, including a heat map generation functionality. HAM’s heat map generator retains accuracy and fast processing speed by utilizing TD’s application programming interface (API) and built-in TD’s “Qflow from Results.” Furthermore, HAM’s heat map output is presented in an easily customizable format in Excel, allowing users to create various custom visual heat maps. A full description of how HAM utilizes TD’s API to create a customizable heat map is provided. A simple model demonstration is included along with step-by-step procedures on creating custom heat maps. HAM’s heat map result has been verified against TD’s and other heat map generation software, and verification methods are also included.

Thermal desktop↗
NASA NTRSDate not supplied

Near-term Persistent Platform Orbital Testbed: Three Candidate Architecture Options

On-orbit Servicing, Assembly, and Manufacturing (OSAM) will revolutionize the space industry by transforming the concept of operations of space systems and enabling new, radically different system implementations. These new implementations will benefit from a novel persistent asset design paradigm which focuses on evolvable designs that are tailored to the operational environment, not the launch environment. In addition, the ability to launch sub-systems independently enable future persistent assets to economically expand in capability and size, achieving cost effective and productive operations lasting for decades like terrestrial observatories. With few exceptions (International Space Station, Hubble Space Telescope, Mission Extension Vehicle customers), current space systems are not visited once they are operational. Leveraging emerging low cost commercial launch provides the ability to repeatedly and routinely revisit space systems. Thus, revolutionary new approaches for space system design are possible, creating completely new opportunities for small businesses and accelerating the growth of already established space industries. To usher in the revolutionary new operational paradigm, two things are needed. First, to build confidence in the technology and new paradigm, there must be a leading example, a bellwether persistent asset, that demonstrates the reliability and maturity of the new persistent asset paradigm (where repeated visits are common). Second, in order to rapidly advance and validate OSAM capabilities, an efficient means is required to conduct tests in the space environment. A persistent platform testbed satisfies both these needs. The space environment exhibits a plethora of characteristics that are difficult and costly to accurately simulate for a full system in a terrestrial laboratory, such as near zero gravity, a wide range of ionizing radiation types, atomic oxygen, and micro-meteoroids and space debris traveling at high velocity. In addition, since persistent assets range in mass from a few grams to several metric tons, it is difficult to accurately simulate interactions between these systems and visiting vehicles (that also exhibit a wide range of varying masses and capabilities). These interactions include the transmission of forces and/or exchanging mass (in the form of instruments, fuel, robotic assets, etc.). Thus, a rapid, versatile and cost efficient in-space testing capability that includes a persistent test platform and a surrounding in-space test zone is needed to mature technologies through experimentation. The testbed can provide common services, such as: power, thermal control, vibration isolation, data transmission between experiments and terrestrial experimenters, station-keeping, pointing, and robotic agents that can be leveraged by customer experiments. The onboard robotic agents can be used to provide payload handling services, such as: assembly, change out or upgrade, relocation, connecting/disconnecting utilities, inspection, repair or servicing, etc. Since the persistent platform cost will be amortized over many hosted payloads, its services can eventually be offered at a price much lower than if one were to design a unique and dedicated spacecraft and mission for those few experiments. The key to achieving an effective testbed is providing efficient cost effective access and infrastructure to a variety of commercial, academic and government customers coupled with extensibility, in the capability of an individual persistent platform test bed or replication of the test bed in a different operational regime. Three potential options for implementing a test bed were developed and evaluated in this study.

Persistent Platform↗
NASA NTRSDate not supplied

Near-term Persistent Platform Orbital Testbed: Three Candidate Architecture Options

On-orbit Servicing, Assembly, and Manufacturing (OSAM) will revolutionize the space industry by transforming the concept of operations of space systems and enabling new, radically different system implementations. These new implementations will benefit from a novel persistent asset design paradigm which focuses on evolvable designs that are tailored to the operational environment, not the launch environment. In addition, the ability to launch sub-systems independently enable future persistent assets to economically expand in capability and size, achieving cost effective and productive operations lasting for decades like terrestrial observatories. With few exceptions (International Space Station, Hubble Space Telescope, Mission Extension Vehicle customers), current space systems are not visited once they are operational. Leveraging emerging low cost commercial launch provides the ability to repeatedly and routinely revisit space systems. Thus, revolutionary new approaches for space system design are possible, creating completely new opportunities for small businesses and accelerating the growth of already established space industries. To usher in the revolutionary new operational paradigm, two things are needed. First, to build confidence in the technology and new paradigm, there must be a leading example, a bellwether persistent asset, that demonstrates the reliability and maturity of the new persistent asset paradigm (where repeated visits are common). Second, in order to rapidly advance and validate OSAM capabilities, an efficient means is required to conduct tests in the space environment. A persistent platform testbed satisfies both these needs. The space environment exhibits a plethora of characteristics that are difficult and costly to accurately simulate for a full system in a terrestrial laboratory, such as near zero gravity, a wide range of ionizing radiation types, atomic oxygen, and micro-meteoroids and space debris traveling at high velocity. In addition, since persistent assets range in mass from a few grams to several metric tons, it is difficult to accurately simulate interactions between these systems and visiting vehicles (that also exhibit a wide range of varying masses and capabilities). These interactions include the transmission of forces and/or exchanging mass (in the form of instruments, fuel, robotic assets, etc.). Thus, a rapid, versatile and cost efficient in-space testing capability that includes a persistent test platform and a surrounding in-space test zone is needed to mature technologies through experimentation. The testbed can provide common services, such as: power, thermal control, vibration isolation, data transmission between experiments and terrestrial experimenters, station-keeping, pointing, and robotic agents that can be leveraged by customer experiments. The onboard robotic agents can be used to provide payload handling services, such as: assembly, change out or upgrade, relocation, connecting/disconnecting utilities, inspection, repair or servicing, etc. Since the persistent platform cost will be amortized over many hosted payloads, its services can eventually be offered at a price much lower than if one were to design a unique and dedicated spacecraft and mission for those few experiments. The key to achieving an effective testbed is providing efficient cost effective access and infrastructure to a variety of commercial, academic and government customers coupled with extensibility, in the capability of an individual persistent platform test bed or replication of the test bed in a different operational regime. Three potential options for implementing a test bed were developed and evaluated in this study.

Persistent Platform↗
NASA NTRSDate not supplied

Utilization of Machine Learning Techniques for Managing the Tracking and Data Relay Satellite Constellation

National Aeronautics and Space Administration’s (NASA) Goddard Space Flight Center (GSFC) operates a constellation of ten geosynchronous Tracking and Data Relay Satellites (TDRS). The TDRS constellation consists of multiple geosynchronous communication relay satellites located around the equator so they can provide continual coverage of any mission in low earth orbit. The TDRS are located primarily in three oceanic regions around the earth. NASA’s White Sands Complex provides the ground communication support for TDRS located over the Atlantic and Pacific Oceans. Another TDRS ground station in Guam supports the TDRS over the Indian Ocean. With these satellites the TDRS network can provide continuous coverage of satellites in low-earth orbit. The NASA Space Network (SN) project office at GSFC manages the constellation of spacecraft. Major customers of the TDRS constellation include, but are not limited to, the International Space Station and the Hubble Space Telescope. The TDRS constellation has three generations of satellites and has been active for over 30 years providing reliable communication links between customer satellites and corresponding ground stations. However, one of the major concerns for TDRS, and in any space mission, is to ensure the health and safety of the spacecraft. Generally, engineers use telemetry data to monitor and analyze the performance and state of health of the spacecraft. Telemetry data contains hundreds of parameters that monitor each important component in the spacecraft, which can be utilized to recognize and characterize the behavior of the spacecraft. Each parameter contains considerable information to represent time-dependent properties of each spacecraft subsystem and component. During the entire life of a TDRS spacecraft, thousands of gigabytes of telemetry data are transmitted in real-time from the spacecraft to the ground station at the White Sands Complex in Las Cruces, New Mexico, and recorded as historical data sets for engineers to process and analyze the events that occurred on-orbit. These parameters contain the function of multiple spacecraft subsystems, such as the attitude control system (ACS), Thermal, Electrical Power Subsystem (EPS), etc. . The first and second generations have exceeded their required lifetime and NASA is keen to manage these spacecrafts carefully in order to maximize the remaining life using the spacecraft telemetry. The challenge is to know when the risk of losing a spacecraft in geosynchronous orbit exceeds the benefit of continued operations for customer support. In the TDRS fleet, the EPS is the most critical subsystem related to spacecraft operations. Failure of the EPS would strand a spacecraft in geosynchronous orbit. Since EPS provides power to the spacecraft, component failures ultimately lead to the inability to support the spacecraft loads and the communications payload. For instance, TDRS-8 has several anomalies in EPS including the Bus Voltage Limiter (BVL) shunt current, solar array loss of circuits, and failed battery cells. Any of these anomalies can cause critical issues to the spacecraft. Therefore, developing a system to analyze and perform early detection of a potential anomaly is an important issue in telemetry data analysis. In recent years, Telemetry Mining (TM) has been proposed to process telemetry data by using Data Mining (DM) techniques such as classification, clustering, regression and anomaly detection. Anomaly detection, also known as outlier detection, has been widely used in many data mining areas such as remote sensing, medical data processing and digital image processing. The goal of anomaly detection is to detect abnormal data, which contains a relatively low probability of occurrence among the entire data set. Early detection of anomalies is one of the most significant issues in managing the spacecraft configuration. If anomalies can be detected early enough, then the redundant resources can be used to extend the life of the operational spacecraft. We present an unsupervised anomaly detection method to process the EPS data extracted from TDRS-8. This is different from traditional analytical methods, which use telemetry data to illustrate behavior and physical meaning of each spacecraft component. TM connects multiple parameters as a vector and then conducts data analysis on this high dimension telemetry vector. This method is looking at the properties of a high dimensional vector that is able to consider the relationship between different parameters in the anomaly detection problem. This kind of method performs much better than the traditional limit checking method. In addition, we propose a new approach of real-time anomaly detection to process telemetry data in real-time, which can then be applied to spacecraft monitoring with high reliability, low cost and high accuracy.

Machine Learning (ML)↗
NASA NTRSDate not supplied

SERFE Thermal Performance Results

NASA has been developing a new spacesuit, called the Exploration Extravehicular Mobility Unit (xEMU) for over a decade. This spacesuit is underdevelopment to support missions to the International Space Station (ISS) and also to the Moon. Improvements in the life and robustness of the Portable Life Support System (PLSS) has been a major objective of these efforts. The Suit Water Membrance Evaporator (SWME) was chosen as the technology to provide cooling to the xEMU and has undergone several iterations of development over this period. An ISS flight experiment centered around the SWME and other thermal loop technologies was developed and has been under test in an ISS EXpedite PRocessing of Experiments to the Space Station (EXPRESS) rack since November of 2020. In addition to the SWME, The SWME EXPRESS Rack Flight Experiment (SERFE) contains several technology demonstrations from the xEMU project and has been demonstrating their performance in micro-gravity and over an extended duration. In addition to the SWME, these include two dissimilar water pumps, custom check valves, custom bypass relieve valves, a custom thermal control valve, development pressure and temperature sensors, and the Thermal Loop Controller. This paper presents thermal and fluids testing results of the system as a whole and of key components.

SERFE↗
NASA NTRS2022

SPARCS Payload Assembly, Integration, and Test Update

The Star-Planet Activity Research CubeSat (SPARCS) is a 6U CubeSat under construction that is devoted to the photometric monitoring of M stars in the far-UV (FUV) and near-UV (NUV), to measure the time-dependent spectral slope, intensity and evolution of low-mass star high-energy radiation. We report on the progress made in the assembly, integration and test of the instrument payload at Arizona State University using a custom TVAC chamber and optical stimulus that provides calibration light sources and the custom contamination control environment that the FUV demands. The payload consists of a custom 90mm clear aperture telescope developed by Hexagon/Sigma Space, combined with a dichroic plate to separate the FUV and NUV beams developed by Teledyne Acton and Materion, married with twin focal plane array cameras separately optimized for their band passes as developed by JPL.

FUV↗
NASA NTRS2022

Rapid Flight Control Law Deployment and Testing Framework for Subscale VTOL Aircraft

A set of procedures was developed to enable rapid flight control law deployment and testing on subscale vertical takeoff and landing (VTOL) aircraft. Low-cost, subscale flight vehicles have become well-suited testbeds for rapid flight dynamics and controls research progression; however, integration of custom flight control laws onto flight hardware has historically been an arduous task. The toolchain described in this report leverages Simulink with the UAV Toolbox, a Pixhawk flight computer running PX4 firmware, and QGroundControl to efficiently design and flight test custom control algorithms. A subscale CL-84 VTOL aircraft was used as a testbed in this investigation to exercise the hardware integration process on a physical model. Implementation of custom attitude stabilization control laws and programmed test input excitations for aircraft system identification were demonstrated using the expeditious hardware integration process. The detailed procedures given in this report are expected to be used in future flight test efforts.

flight testing↗
NASA NTRSDate not supplied

Evaluation of the NASA Artemis Regions of Interest for ISRU Water Mine Potential

The NASA Artemis Campaign has a stated goal to return to the Moon to maintain a sustainable presence; In-Situ Resource Utilization (ISRU) is a key part of sustainability. The regions of interest identified for the Artemis campaign are at Lunar the South Pole where water ice, a valuable resource for ISRU, has been identified. As such, a preliminary evaluation of the ISRU ice mining potential has been performed for of these regions of interest. A set of ground rules for this evaluation were developed to align with current assumptions for customer needs, hardware capabilities, an initially limited infrastructure, and lunar environments/terrain. These ground rules, and the evaluation of six regions of interest, are presented here. The site selections (ISRU and customer assets) and their associated traverses are notional and were intended only to provide a broad preliminary evaluation of the water ISRU potential of the regions. Evaluation of these regions are subject to change as decisions regarding utilization are made. Water ISRU is possible at all regions, though the degree to which each criterion are met is variable. The two regions near Shackleton ranked highest in this evaluation, while the de Gerlache region presented the most difficulties meeting the current criteria. The regions were not explicitly ranked due to the nuances associated with the high number of variables but evaluation summaries of each are presented. It should also be noted that all ISRU ‘mine’ sites in this analysis focused on smaller (few kilometer) size permanently shadowed regions (PSRs). This was necessary to meet proximity requirements between these PSRs and the highly illuminated regions needed for customers and ISRU processing. The areas identified in this study are meant to focus exploration and reconnaissance efforts needed to better evaluate the ISRU potential.

In-situ resource utilization↗
NASA NTRSDate not supplied

Evaluation of the NASA Artemis Regions of Interest for ISRU Water Mine Potential

The NASA Artemis Campaign has a stated goal to return to the Moon to maintain a sustainable presence; In-Situ Resource Utilization (ISRU) is a key part of sustainability. The regions of interest identified for the Artemis campaign are at Lunar the South Pole where water ice, a valuable resource for ISRU, has been identified. As such, a preliminary evaluation of the ISRU ice mining potential has been performed for of these regions of interest. A set of ground rules for this evaluation were developed to align with current assumptions for customer needs, hardware capabilities, an initially limited infrastructure, and lunar environments/terrain. These ground rules, and the evaluation of six regions of interest, are presented here. The site selections (ISRU and customer assets) and their associated traverses are notional and were intended only to provide a broad preliminary evaluation of the water ISRU potential of the regions. Evaluation of these regions are subject to change as decisions regarding utilization are made. Water ISRU is possible at all regions, though the degree to which each criterion are met is variable. The two regions near Shackleton ranked highest in this evaluation, while the de Gerlache region presented the most difficulties meeting the current criteria. The regions were not explicitly ranked due to the nuances associated with the high number of variables but evaluation summaries of each are presented. It should also be noted that all ISRU ‘mine’ sites in this analysis focused on smaller (few kilometer) size permanently shadowed regions (PSRs). This was necessary to meet proximity requirements between these PSRs and the highly illuminated regions needed for customers and ISRU processing. The areas identified in this study are meant to focus exploration and reconnaissance efforts needed to better evaluate the ISRU potential.

In-situ resource utilization↗
NASA NTRS2023

SERFE PLSS Component Lessons Learned from ISS

NASA has been developing a new spacesuit, called the Exploration Extravehicular Mobility Unit (xEMU) for over a decade. This spacesuit is under development to support missions to the International Space Station (ISS) and also to the Moon. Improvements in the life and robustness of the Portable Life Support System (PLSS) has been a major objective of these efforts. The Suit Water Membrane Evaporator (SWME) was chosen as the technology to provide cooling to the xEMU and has undergone several iterations of development over this period. An ISS flight experiment centered around the SWME and other thermal control loop (TCL) technologies was developed and tested in an ISS EXpedite PRocessing of Experiments to the Space Station (EXPRESS) rack from November of 2020 to August of 2022. In addition to the SWME, the SWME EXPRESS Rack Flight Experiment (SERFE) contains several technologies from the xEMU project and demonstrated their performance in micro-gravity and over an extended duration. These included two dissimilar water pumps, custom check valves, custom bypass relieve valves, a custom thermal control valve, development pressure and temperature sensors, and the thermal loop controller. This paper presents PLSS component lessons learned after return of the SERFE flight unit in August of 2022. The SERFE team took the flight unit apart and handed hardware components over to hardware owners to see how parts of the TCL managed after almost 2 years on the ISS and 25 simulated EVAs (Exploration Extravehicular Activity) on orbit. The team performed inspection, testing, and analysis and provided lessons learned on PLSS components for NASA’s prototype spacesuit. This analysis included how well SWME maintained its heat rejection capability, as well as looked at the robustness of the other TCL hardware.

SERFE↗
NASA NTRS2022

Assurance Equations: A Cost and Criticality Model for Optimizing Quality Assurance Surveillance

The cost of quality vs cost of failure correction has been a long-running topic of discussion within the Aerospace community. It leads directly to concepts of “risk tolerance”, and risk-based decision-making. It would be valuable if there was a way to compute the optimal investment in customer-executed quality assurance activities using defect significance with respect to performance objectives, the activities’ defect detection effectiveness, and the cost-penalty for late discovery of impactful defects. This optimization is particularly of interest to projects whose budget constraints significantly limit their risk management options.The cost to fix defects (i.e., failure correction) escalates as the project matures. There have been studies attempting to determine the relative cost of fixing defects discovered during various phases of a project life cycle with important implications, all of which suggest growth factors are large. The commonly referred to 1:10:100 rule represents a cost multiplier for repair/rework across the Design to Fab to Test hardware development phases. Cost premiums for QA activities also accumulate when they are treated as mandatory (due to schedule drag) or are performed later than their assigned phase.This paper describes the modeling of development phase -dependencies in the conduct of typical customer-executed quality assurance activities. Our initial modeling encompasses:• Distinct phases of the production lifecycle• Multiple kinds of Defects, each with some a-priori likelihood of being present• Each defect’s impact on performance Objectives for a type of hardware• The cost and efficacy of assurance techniques at detecting such Defects• The costs of fixing those Defects detected in a given phase of the production lifecycleThe model captures assurance activities’ abilities to Detect defects. Upon detection it is assumed that the Defect is immediately fixed. Defects that “escape” detection by some activity may thereafter be detected by a later activity, but by then the cost of fixing the Defect may have escalated. Defects are related to the performance Objectives they would detract from, were those Defects to remain present in the operating system.We have constructed and are exploring, a model that relates the importance of hardware system elements to mission objectives, the impact of types of Defects on those hardware types, the cost of customer-executed assurance activities (i.e., supplier controls) and their effectiveness towards reducing an impactful quality escape, and the cost of Defect correction across production phase. We describe the approach taken to select the key model aspects, why they are relevant to our NASA mission, and our efforts to populate it with relevant and contemporary data. We use a notional example to illustrate model design and function.

Plante, Jeannette↗
NASA NTRS2022

Mars 2020 Perseverance Rover SHERLOC Instrument Isolation System

The NASA Jet Propulsion Laboratory (JPL) successfully landed the Mars 2020 Perseverance Rover at Jezero Crater on the Martian surface. Perseverance’s main mission objective is to cache Martian rock and regolith samples in hermetically sealed tubes to be brought back to Earth by future missions. To achieve this goal the rover is equipped with a 2-meter-long Robotic Arm (RA) which manipulates the Turret to interact with the surface. The Turret is comprised of science instruments and tools that enable surface sampling and science. The backbone of the Turret hardware is the Rotary Percussive Coring Drill. The science instruments, which are directly mounted to the structural housing of this drill, must be able to withstand not only the launch and entry, descent and landing (EDL) loads of the vehicle but also the dynamic percussive environment, induced by the drill throughout surface operations. This paper discusses the technical hardware design, development and testing of a vibration isolation system to protect the Scanning Habitable Environments with Raman and Luminescence for Organics and Chemicals (SHERLOC) Instrument from these dynamic environments. The hardware design aspect of this problem was limited by both size and mass constraints. The Turret is tightly configured and the physical space in which hardware can reside is restricted due to multiple axes of surface interaction points. Another driving requirement is the extreme range of thermal non-operational environment from -135C to +90C. This, in addition to SHERLOC being a heavier instrument than previously integrated on a turret, made the use of isolation systems employed on previous rover missions problematic. The final design incorporates custom wire mesh springs preloaded within titanium hexapod struts equipped with flexure ends. Custom versions of commercially available wire mesh springs were designed and tested. These custom springs differed in dimension, density and stiffness from the off the shelf options. The newly designed springs went through various stages of flight acceptance testing. Detailed physics-based modeling to understand what loads the isolation system would experience was used to define the test conditions for the springs and entire isolation subsystem. The testing program developed around this was extensive to fully characterize the isolation performance over cleanliness levels, temperature and life. Another major aspect of this work was developing a method of replicating the drill’s percussive environment for performance and life testing of Turret mounted hardware. Attaching the instrument to an operating drill for testing was not a viable option. A method of using a Highly Accelerated Life Test (HALT) table was developed and applied across the project as the most representative and tunable option to physically simulate this new environment. This method, along with launch environment random vibration testing, was used to build an entire dynamic qualification and flight hardware test program. The results of the design, modeling, testing and analysis of the SHERLOC Isolation System is described throughout the following paper.

Krafchak, Todd↗
NASA NTRS2023

SERFE PLSS Component Lessons Learned from ISS

NASA has been developing a new spacesuit, called the Exploration Extravehicular Mobility Unit (xEMU) for over a decade. This spacesuit is under development to support missions to the International Space Station (ISS) and also to the Moon. Improvements in the life and robustness of the Portable Life Support System (PLSS) has been a major objective of these efforts. The Suit Water Membrane Evaporator (SWME) was chosen as the technology to provide cooling to the xEMU and has undergone several iterations of development over this period. An ISS flight experiment centered around the SWME and other thermal control loop (TCL) technologies was developed and tested in an ISS EXpedite PRocessing of Experiments to the Space Station (EXPRESS) rack from November of 2020 to August of 2022. In addition to the SWME, the SWME EXPRESS Rack Flight Experiment (SERFE) contains several technologies from the xEMU project and demonstrated their performance in micro-gravity and over an extended duration. These included two dissimilar water pumps, custom check valves, custom bypass relieve valves, a custom thermal control valve, development pressure and temperature sensors, and the thermal loop controller. This paper presents PLSS component lessons learned after return of the SERFE flight unit in August of 2022. The SERFE team took the flight unit apart and handed hardware components over to hardware owners to see how parts of the TCL managed after almost 2 years on the ISS and 25 simulated EVAs (Exploration Extravehicular Activity) on orbit. The team performed inspection, testing, and analysis and provided lessons learned on PLSS components for NASA’s prototype spacesuit. This analysis included how well SWME maintained its heat rejection capability, as well as looked at the robustness of the other TCL hardware.

SERFE↗
NASA NTRS2024

3D Scanning System to Assess Gravity-Dependent Body Shape Changes

The human body shows unique physiological and morphological changes when exposed to different gravity conditions, including muscle atrophy, fluid shift, spinal elongation, and body posture adjustments. Such changes need to be incorporated for human-system integration in the vehicle habitat, garment, and spacesuit designs, as inaccurate body measurements can result in suboptimal crew protection that can potentially decrease injury tolerance. However, the traditional linear measurements, such as stature, segment lengths or circumferences measured using a caliper or tape measure, often show limited consistency and are unable to capture the nonlinear characteristics of the human body. While 3D body scanning can provide significant advantages over linear measurements, the technologies have not been fully developed or customized for in-flight scanning. For ground laboratory use, several different scanner types are commercially available. However, in-flight scanning requires additional technical considerations, such as minimal scan time, simplified calibration, and sufficient capture volume. This work aims to develop a prototype 3-D body scanning system that is customized for in-flight use to scan crewmembers, with the configuration and performance optimized for detecting known gravity-dependent body shape and posture changes. A hardware system will be custom built using a network of commercial off-the-shelf 3D sensors. The sensor parameters and settings will be optimized to detect the targeted body shape changes, specifically using body manikins of which the shape and size are iteratively permuted to simulate the known changes by fluid shift and spinal elongation. The capture volume will be also matched for a range of body sizes from a 1st percentile female to 99th percentile male. Unintentional body motions or floating in microgravity will be also simulated and incorporated. A data acquisition software will be developed for efficient in-flight operations with minimal overhead and easy-to-use user interface. A simplified calibration procedure will be designed for robust scanning against frequent vibration or unexpected sensor position shifts. The system will be tested in the ground laboratory for accuracy and reliability against a reference scanning system. New anthropometry measurements will be also identified to sensitively capture the gravity dependent body shape changes, in addition to the traditional anthropometry measurements. A novel landmark-based technique will be tested for consistent anthropometry measurements across posture variations. If successfully developed and deployed, the new system is expected to provide previously unavailable body shape and size data from different gravitational environments, including 0-g, 1/6-g, and 1-g. Such data can improve suit fit, habitat design, exercise efficacy quantification and sizing of orthostatic intolerance garments.

K H Kim↗
NASA NTRS2013

Electrical Impedance Tomography Technology: 2013 Center Innovation Fund Final Report

Electrical impedance tomography is a medical noninvasive imaging technology which has advantages over other medical imaging technologies for medically safe long term real time internal imaging monitoring applications in human patients. The technology is much more compact, portable, low power and potentially more low cost compared to other medical image technologies, making it very well suited for medical aerospace and spaceflight applications. EIT technology’s main drawback has been low image resolution, and consequently improving EIT resolution is the primary research goal, as well as increasing imaging speed for real time animation imaging. In a relatively short time the BERL group has brought together design plans, technical resources and has built and tested hardware with the purpose of improving EIT imaging technology. EIT prototype system development plans and system designs have been made to target needed EIT technical improvement in electronic and computer hardware as well as EIT software technology. New hardware design and fabrication resources and technologies have been brought together through resourceful use of existing equipment and software at BERL, and a significant advance has been made in custom electronic hardware prototyping capabilities in collaboration with EFAL, for mutual benefit for both NASA KSC laboratories. BERL has gained significant EIT software capability and tested EIT imaging algorithm code through collaboration with an internationally recognized EIT software development and research forum. A new custom workstation has been developed, built and tested using internal resources, equipment and expertise, that includes a new state-of-the-art massively parallel technology that is commercially available. Custom prototype hardware has been designed and tested, a high priority electronic design, key to improving electronic performance and image quality, has been researched and tested in four designs, with a summary of test results of the selected design illustrated here. The selected design performance exceeds the developed EIT design hardware specifications.

Michael R Lapointe↗
NASA NTRS2024

SMAnalytics Automated Shape Memory Test Analysis Software User's Manual: UCFTC, UPER, and DSC Test Methods, Version 1.0.2

Over the course of 60 years of shape memory alloy research and development, the properties of these alloys have been measured using various testing methods, which are often customized by the organization performing the test. However, commercial adoption of shape memory alloys in aeronautic actuator applications requires reducing property uncertainty through standardizing test methods. Historically, differential scanning calorimetry (DSC) has been used to measure transformation temperatures under stress-free conditions. This testing method is well established, and tests are run under the applicable standard, ASTM F2004-17: Standard Test Method for Transformation Temperature of Nickel-Titanium Alloys by Thermal Analysis. Two other test methods for measuring strains and transformation temperatures under constant load or free recovery after prestraining have only recently been standardized—ASTM E3097: Standard Test Method for Mechanical Uniaxial Constant Force Thermal Cycling of SMAs (UCFTC) and ASTM E3098: Standard Test Method for Mechanical Uniaxial Pre-Strain and Thermal Free Recovery of SMAs (UPFR). These standards represent a critical step forward in producing reliable material property data for the use of these alloys in aeronautics and other commercial areas. However, no standard programs or software packages were previously available for postprocessing UCFTC- and UPFR-type test data to extract property data. Each organization that performed the testing analyzed data using its own custom manual methods, such as using a plot and a straight edge, spreadsheet plotting methods, or custom code routines, to extract the required values for strains, stresses, and transformation temperatures. SMAnalytics represents the first publicly available uniform software package for processing data generated using the DSC, UCFTC, and UPFR test methods, as well as many modifications of these methods, including loading in martensite versus austenite and performing multiple thermal cycles at stress. In doing so, it provides a tool for reducing potential error or variability in the measured values due to the precision of the technique used and person-to-person variability. It is also expected that this automated data-parsing tool can accelerate the data analysis phase of the test campaign, especially for large data files. This User’s Manual describes how the SMAnalytics software works and the method for its use.

Shape Memory Alloy↗
NASA NTRS2024

3D Scanning System to Assess Gravity-Dependent Body Shape Changes

The human body shows unique physiological and morphological changes when exposed to different gravity conditions, including muscle atrophy, fluid shift, spinal elongation, and body posture adjustments. Such changes need to be incorporated for human-system integration in the vehicle habitat, garment, and spacesuit designs, as inaccurate body measurements can result in suboptimal crew protection that can potentially decrease injury tolerance. However, the traditional linear measurements, such as stature, segment lengths or circumferences measured using a caliper or tape measure, often show limited consistency and are unable to capture the nonlinear characteristics of the human body. While 3D body scanning can provide significant advantages over linear measurements, the technologies have not been fully developed or customized for in-flight scanning. For ground laboratory use, several different scanner types are commercially available. However, in-flight scanning requires additional technical considerations, such as minimal scan time, simplified calibration, and sufficient capture volume. This work aims to develop a prototype 3-D body scanning system that is customized for in-flight use to scan crewmembers, with the configuration and performance optimized for detecting known gravity-dependent body shape and posture changes. A hardware system will be custom built using a network of commercial off-the-shelf 3D sensors. The sensor parameters and settings will be optimized to detect the targeted body shape changes, specifically using body manikins of which the shape and size are iteratively permuted to simulate the known changes by fluid shift and spinal elongation. The capture volume will be also matched for a range of body sizes from a 1st percentile female to 99th percentile male. Unintentional body motions or floating in microgravity will be also simulated and incorporated. A data acquisition software will be developed for efficient in-flight operations with minimal overhead and easy-to-use user interface. A simplified calibration procedure will be designed for robust scanning against frequent vibration or unexpected sensor position shifts. The system will be tested in the ground laboratory for accuracy and reliability against a reference scanning system. New anthropometry measurements will be also identified to sensitively capture the gravity dependent body shape changes, in addition to the traditional anthropometry measurements. A novel landmark-based technique will be tested for consistent anthropometry measurements across posture variations. If successfully developed and deployed, the new system is expected to provide previously unavailable body shape and size data from different gravitational environments, including 0-g, 1/6-g, and 1-g. Such data can improve suit fit, habitat design, exercise efficacy quantification and sizing of orthostatic intolerance garments.

K H Kim↗