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At least 721 records · Page 40

LDEF electronic systems: Successes, failures and lessons

Following LDEF retrieval, a series of tests were performed of various NASA and experimenter electronics, including the NASA provided data and initiate systems. The post-flight test program objectives and observations are discussed, as well as the 'lessons learned' from these examinations. Results are also included of an evaluation of electronic hardware flown on Boeing's LDEF experiment. Overall the electronic systems performed remarkably well, even though most were developed under budget restraints and used some non-space qualified components. Several anomalies were observed, however, including some which resulted in loss of data. Suggestions for avoiding similar problems on future programs are presented.

Miller, E. A.↗

Hubble Space Telescope Thermal Blanket Repair Design and Implementation

Substantial damage to the outer layer of Hubble Space Telescope (HST) thermal blankets was observed during the February 1997 servicing mission. After six years in LEO, many areas of the aluminized Teflon(R) outer blanket layer had significant cracks, and some material was peeled away to expose inner layers to solar flux. After the mission, the failure mechanism was determined, and repair materials and priorities were selected for follow-on missions. This paper focuses on the thermal, mechanical, and EVA design requirements for the blanket repair, the creative solutions developed for these unique problems, hardware development, and testing.

Ousley, Wes↗

Development of the Electron Drift Instrument (EDI) for Cluster

The Electron Drift Instrument (EDI) is a new technique for measuring electric fields in space by detecting the effect on weak beams of test electrons. This U.S. portions of the technique, flight hardware, and flight software were developed for the Cluster mission under this contract. Dr. Goetz Paschmann of the Max Planck Institute in Garching, Germany, was the Principle Investigator for Cluster EDI. Hardware for Cluster was developed in the U.S. at the University of New Hampshire, Lockheed Palo Alto Research Laboratory, and University of California, San Diego. The Cluster satellites carrying the original EDI instruments were lost in the catastrophic launch failure of first flight of the Arianne-V rocket in 1996. Following that loss, NASA and ESA approved a rebuild of the Cluster mission, for which all four satellites were successfully launched in the Summer of 2000. Limited operations of EDI were also obtained on the Equator-S satellite, which was launched in December, 1997. A satellite failure caused a loss of the Equator-S mission after only 5 months, but these operations were extremely valuable in learning about the characteristics and operations of the complex EDI instrument. The Cluster mission, satellites, and instruments underwent an extensive on-orbit commissioning phase in the Fall of 2000, carrying over through January 2001. During this period all elements of the instruments were checked and careful measurements of inter-experiments interferences were made. EDI is currently working exceptionally well in orbit. Initial results verify that all aspects of the instrument are working as planned, and returning highly valuable scientific information. The first two papers describing EDI on-orbit results have been submitted for publication in April, 2001. The principles of the EDI technique, and its implementation on Cluster are described in two papers by Paschmann et al., attached as Appendices A and B. The EDI presentation at the formal Cluster Commissioning Review, held at ESA Headquarters in Paris, is attached as Appendix C.

Quinn, Jack↗

Intersection Monitor for Traffic-Light-Preemption System

The figure shows an intersection monitor that is a key subsystem of an emergency traffic-light-preemption system that could be any of the systems described in the three immediately preceding articles and in Systems Would Preempt Traffic Lights for Emergency Vehicles (NPO-30573), NASA Tech Briefs, Vol. 28, No. 10 (October 2004), page 36. This unit is so named because it is installed at an intersection, where it monitors the phases (in the sense of timing) of the traffic lights. The mode of operation of this monitor is independent of the type of traffic-light-controller hardware or software in use at the intersection. Moreover, the design of the monitor is such that (1) the monitor does not, by itself, affect the operation of the traffic- light controller and (2) in the event of a failure of the monitor, the trafficlight controller continues to function normally (albeit without preemption). The monitor is installed in series with the traffic-light controller at an intersection. The control signals of interest are monitored by use of high-impedance taps on affected control lines. These taps are fully isolated and further protected by high-voltage diodes that prevent any voltages or short circuits that arise within the monitor from affecting the controller. The signals from the taps are processed digitally and cleaned up by use of high-speed logic gates, and the resulting data are passed on to other parts of the traffic-light-preemption intersection subsystem. The data are compared continuously with data from vehicles and used to calculate timing for reliable preemption of the traffic lights. The pedestrian crossing at the intersection is also monitored, and pedestrians are warned not to cross during preemption.

Bachelder, Aaron↗

Simulation Studies for an Urban Air Mobility Aircraft using Hardware-In-Loop Experiments

Urban Air Mobility seeks to transport passengers, deliver cargo, and provide emergency transportation in major metropolitan areas. This will be accomplished with distributed electric-powered vertical takeoff and landing aircraft. The low specific energy of the current generation lithium-ion battery packs limit the operational range of electric aircraft. Limited range impacts safety by reducing the time available for analyzing and responding to errors and failures, and limiting the ability to fly to an alternative landing area or return to base. It is therefore critical to understand flight operational and environmental conditions that impact the onboard lithium-ion polymer battery pack’s health. With this as the motivation, experimental procedure in a laboratory setting, and results of the experiments performed on battery packs subject to power draw corresponding to power required during the different phases of flight of a NASA conceptual quadrotor aircraft in simulation are described. The fully charged battery is allowed to discharge at specific C-rates based on the power draw profile and the current and voltages are recorded. Observed results under different operating conditions and mission profiles are discussed.

UAM↗

Shooting the Moon

This story is about an unlikely NASA mission to the Moon. It was unlikely because it was started with far too little time and too-little money to complete. It was unlikely because it was able to take chances to accept risk of failure. It was unlikely because it was searching for the unthinkable: water-ice on the moon... Figure 1-1: LCROSS Mission. The mission of the Lunar CRater Observation and Sensing Satellite (LCROSS) was to investigate the possibility of water ice in craters on the Moon s poles. This is certainly an interesting scientific topic in itself, but I intend to focus on the compelling experience of managing the LCROSS Project in the context of this storied Agency. Perhaps most interesting are the implications this story has for managing any development effort, lunar or not, and working a balance to achieve success. NASA is by design a risk-taking agency within the US Government. It could be argued that NASA s purpose in the aerospace community is to take on the really big challenges that either the corporate world can t afford, are not yet profitable endeavors, or are just too risky for private corporations to entertain. However, expectations of the Agency have evolved. A combination of grim human tragedies and some very public cost and schedule overruns have challenged the public s and Congress s tolerance for risk-taking within the Agency. NASA, which is supposed to be in the business of taking risks to do bold, difficult things, has become less and less able to do so within its cost framework. Yet effectively replacing prudent risk management with attempts to "risk-eliminate" is completely unaffordable. So where does risk-taking fit within the Agency, or within private/corporate organizations for that matter? Where astronauts play there is clearly concern about risk. When an organization puts humans in harm s way, it is understandably going to take extra effort to assure nobody gets hurt. Doing so, of course, costs money - a lot of money to pay for labor and hardware which is attempting to assure nothing will go wrong. Sophisticated designs, with doubly- or triply-redundant systems, extensive testing to verify those systems, and numerous engineering test units built to learn and evolve a hardware design, all drive the cost and time required to implement. Human spaceflight is an expensive business because of the exceptional system complexity and levels of assurance required for human space travel. What about missions that do not involve human spaceflight? What about missions whose potential failure will not take a human life, whose costs are small and whose urgency and importance are limited by design? A portfolio consisting of this type of mission can be designed to be risk tolerant, not requiring large expenditures to guarantee against failure. With the money saved, the number of missions that can be executed within the portfolio grows, or the total cost of the portfolio can be reduced. The NASA LCROSS mission is a pathfinder example of a low-cost, quick turn-around mission which struck a balance on mission risk, while accomplishing big objectives, like defining how we understand the Moon.

Andrews, Daniel R.↗

STARPAHC Interim Evaluation Report, May 1975 - April 1976

The primary goals of the STARPAHC Program are to provide data for developing health care for future manned spacecraft, and to establish the feasibility of the STARPAHC concept for improving the delivery of health care to remote areas on earth. Accordingly, the hardware and medical evaluations initiated during the first 6 months of system operation were continued and expanded during the second 6-month period. The evaluations are based on what has proven to be a relatively stabilized 6-month period wherein system failures which occurred during the initial shakedown period in the first 6 months have been minimized. Early trends and performance data reported in the first semi-annual report were reexamined to either verify, modify or change earlier conclusions. The highlights are given of the total year of operation with emphasis on comparisons between the first and second semi-annual reporting period. In addition, an early analysis of costs is summarized.

Source record↗

Choosing reliability level for Shuttle-carried payloads

The paramount importance of high payload reliability is questioned in the light of payload recoverability in Spacelab and Space Shuttle experiments, and cost effectiveness through less stringent reliability requirements backed up by recovery and reflight of the experiment if necessary is considered. Ground rules and parameters for assessing reliability and recoverability in relation to mission cost effectiveness are advanced. Mission success probability (for one or several flights), experiment hardware cost, design reliability, cost of orbiting the experiment, support system reliability, and other relevant parameters are identified and discussed, and graphs of experimental total cost envelope are plotted. It is proposed that reliability and quality assurance standards be weighed against failure costs and penalties in the case of recoverable space systems.

Campbell, J. W.↗

Status report on a real time Engine Diagnostics Console for rocket engine exhaust plume monitoring

This paper describes the work done on the Engine Diagnostics Console during the past year of development at Stennis Space Center. The Engine Diagnostics Console (EDC) is a hardware and software package which provides near real time monitoring of rocket engine exhaust plume emissions during ground testing. The long range goal of the EDC development program is to develop an instrument that can detect engine degradation leading to catastrophic failure, and respond by taking preventative measures. The immediate goal for the past year's effort is the ability to process spectral data, taken from a rocket engine's exhaust plume, and to identify in an automated and high speed manner, the elemental species and multielemental materials that are present in the exhaust plume.

Bircher, F. E.↗

White Light Used to Enable Enhanced Surface Topography, Geometry, and Wear Characterization of Oil-Free Bearings

A new optically based measuring capability that characterizes surface topography, geometry, and wear has been employed by NASA Glenn Research Center s Tribology and Surface Science Branch. To characterize complex parts in more detail, we are using a three-dimensional, surface structure analyzer-the NewView5000 manufactured by Zygo Corporation (Middlefield, CT). This system provides graphical images and high-resolution numerical analyses to accurately characterize surfaces. Because of the inherent complexity of the various analyzed assemblies, the machine has been pushed to its limits. For example, special hardware fixtures and measuring techniques were developed to characterize Oil- Free thrust bearings specifically. We performed a more detailed wear analysis using scanning white light interferometry to image and measure the bearing structure and topography, enabling a further understanding of bearing failure causes.

Lucero, John M.↗

Design and Certification of the Extravehicular Activity Mobility Unit (EMU) Water Processing Jumper

The Extravehicular Mobility Units (EMUs) onboard the International Space Station (ISS) experienced a failure due to cooling water contamination from biomass and corrosion byproducts forming solids around the EMU pump rotor. The coolant had no biocide and a low pH which induced biofilm growth and corrosion precipitates, respectively. NASA JSC was tasked with building hardware to clean the ionic, organic, and particulate load from the EMU coolant loop before and after Extravehicular Activity (EVAs). Based on a return sample of the EMU coolant loop, the chemical load was well understood, but there was not sufficient volume of the returned sample to analyze particulates. Through work with EMU specialists, chemists, (EVA) Mission Operations Directorate (MOD) representation, safety and mission assurance, astronaut crew, and team engineers, requirements were developed for the EMU Water Processing hardware (sometimes referred to as the Airlock Coolant Loop Recovery [A/L CLR] system). Those requirements ranged from the operable level of ionic, organic, and particulate load, interfaces to the EMU, maximum cycle time, operating pressure drop, flow rate, and temperature, leakage rates, and biocide levels for storage. Design work began in February 2005 and certification was completed in April 2005 to support a return to flight launch date of May 12, 2005. This paper will discuss the details of the design and certification of the EMU Water Processing hardware and its components

Peterson, Laurie J.↗

Lightweight Thrust Chamber Assemblies using Multi-Alloy Additive Manufacturing and Composite Overwrap

Additive Manufacturing (AM) has brought significant design and fabrication opportunities for complex components with internal features such as liquid rocket engine thrust chambers not previously possible. This technology allows for significant cost savings and schedule reductions in addition to new performance optimization through weight reduction and increased margins. Specific to regeneratively-cooled combustion chambers and nozzles for liquid rocket engines, additive manufacturing offers the ability to form the complex internal coolant channels and the closeout of the channels to contain the high pressure liquid propellants with a single operation. Much of additive manufacturing development has focused on monolithic alloys using Laser Powder Bed Fusion (L-PBF), which do not allow for complete optimization of the structure. The National Aeronautics and Space Administration (NASA) completed feasibility of an AM bimetallic L-PBF GRCop-84 copper-alloy combustion chamber with an AM electron beam freeform Inconel 625 structural jacket under the Low Cost Upper Stage Propulsion (LCUSP) Project. A follow-on project called Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) is under development to further expand large-scale multi-alloy thrust chambers while maturing composite overwrap technology for significant weight savings opportunities. The RAMPT project has three primary objectives: 1) Advancing blown powder Directed Energy Deposition (DED) to fabricate integral-channel large scale nozzles, 2) Develop composite overwrap technology to reduce weight and provide structural capability for thrust chamber assemblies, and 3) Develop bimetallic and multi-metallic additively manufactured radial and axial joints to optimize material performance. In addition to these primary manufacturing developments, analytical modeling efforts compliment the process development to simulate the AM processes to reduce build failures and distortions. The RAMPT project is also maturing the supply chain for various manufacturing processes described above in addition to L-PBF of GRCop-42. This paper will present an overview of the RAMPT project, the process development and hardware progress to date, material and hot-fire testing results, along with future developments.

Additive Manufacturing↗

A Case for Developing a Ground Based Replication of the Earth, Moon and Mars Spaceflight Infrastructure

When the systems are developed and in place to provide the services needed to operate en route and on the Lunar and Martian surfaces, an Earth based replication will need to be in place for the safety and protection of mission success. The replication will entail all aspects of the flight configuration end to end but will not include any closed loop systems. This would replicate the infrastructure from Lunar and Martian robots, manned surface excursions, through man and unmanned terrestrial bases, through the various types of communication systems and technologies, manned and un-manned space vehicles (large and small), to Earth based systems and control centers. An Earth based replicated infrastructure will enable checkout and test of new technologies, hardware, software updates and upgrades and procedures without putting humans and missions at risk. Analysis of events, what ifs and trouble resolution could be played out on the ground to remove as much risk as possible from any type of proposed change to flight operational systems. With adequate detail, it is possible that failures could be predicted with a high probability and action taken to eliminate failures. A major factor in any mission to the Moon and to Mars is the complexity of systems, interfaces, processes, their limitations, associated risks and the factor of the unknown including the development by many contractors and NASA centers. The need to be able to introduce new technologies over the life of the program requires an end to end test bed to analyze and evaluate these technologies and what will happen when they are introduced into the flight system. The ability to analyze system behaviors end to end under varying conditions would enhance safety e.g. fault tolerances. This analysis along with the ability to mine data from the development environment (e.g. test data), flight ops and modeling/simulations data would provide a level of information not currently available to operations and astronauts. In this paper we will analyze the beginnings of such a replication and what it could do in terms of reducing risk in the near term for development. We will analyze the Space Shuttle Main Engine (SSME) test lab which has to a large extent accomplished this replication for the SSME and has been highly successful in analyzing hardware and software problems and changes. The cost of replicating the flight system as proposed here could be very high if attempted as an afterthought. We will describe the initial steps for the development of a replication of this infrastructure starting with the communication infrastructure. The Constellation of Labs (CofL) under the Command, Control, Communication and Information (C3I) project for the NASA Exploration Initiative will provide the initial foundation upon which to base this replication. Simply put, there is very little margin for error in high latency situations e.g. en-route to/from Mars or in an autonomous process on the Lunar far side. Any thought out approach to reduce risk and increase safety needs to be accomplished end to end with the actual systems configuration.

Bradford, Robert N.↗

Test program to provide confidence in liquid oxygen cooling of hydrocarbon fueled rocket thrust chambers

An experimental program has been planned at the NASA Lewis Research Center to build confidence in the feasibility of liquid oxygen cooling for hydrocarbon fueled rocket engines. Although liquid oxygen cooling has previously been incorporated in test hardware, more runtime is necessary to gain confidence in this concept. In the previous tests, small oxygen leaks developed at the throat of the thrust chamber and film cooled the hot-gas side of the chamber wall without resulting in catastrophic failure. However, more testing is necessary to demonstrate that a catastrophic failure would not occur if cracks developed further upstream between the injector and the throat, where the boundary layer has not been established. Since under normal conditions cracks are expected to form in the throat region of the thrust chamber, cracks must be initiated artificially in order to control their location. Several methods of crack initiation are discussed in this report. Four thrust chambers, three with cracks and one without, should be tested. The axial location of the cracks should be varied parametrically. Each chamber should be instrumented to determine the effects of the cracks, as well as the overall performance and durability of the chambers.

Armstrong, E. S.↗

Space Station long term lubrication analysis. Phase 1 preliminary tribological survey

Increases in the size, complexity, and life requirements of satellites and space vehicles have put increasing demands on the lubrication requirements for trouble-free service. Since the development costs of large systems are high, long lives with minimum maintenance are dictated. The Space Station represents the latest level of size and complexity in satellite development; it will be nearly 100 meters in major dimensions and will have a life requirement of thirty years. It will have numerous mechanisms critical to its success, some of which will be exposed to the space environment. Designing long-life lubrication systems and choosing appropriate lubricants for these systems will be necessary for their meeting the requirements and for avoiding failures with associated dependent mechanisms. The purpose of this program was to identify the various critical mechanisms and review their designs during the overall design and development stage so that problem areas could be avoided or minimized prior to the fabrication of hardware. The specific objectives were fourfold: (1) to perform a tribology survey of the Space Station for the purpose of documenting each wear point as to materials involved, environmental conditions, and operating characteristics; (2) to review each wear point (point of relative motion) as to the lubrication used and substrate materials selected in the context of its operating characteristics and the environmental conditions imposed; (3) to make recommendations for improvement in areas where the lubricant chosen and/or where the substrate (materials of the wear couple) are not considered optimum for the application; and (4) to make or recommend simulated or full scale tests in tribological areas where the state-of-the-art is being advanced, in areas where new designs are obviously being employed and a critical review would indicate that problems are a strong possibility, and/or where excessive wear, a malfunction, or excessive leakage would create fluid systems problems or contamination of exposed optical equipment.

Dufrane, K. F.↗

Reducing the cognitive workload: Trouble managing power systems

The complexity of space-based systems makes monitoring them and diagnosing their faults taxing for human beings. Mission control operators are well-trained experts but they can not afford to have their attention diverted by extraneous information. During normal operating conditions monitoring the status of the components of a complex system alone is a big task. When a problem arises, immediate attention and quick resolution is mandatory. To aid humans in these endeavors we have developed an automated advisory system. Our advisory expert system, Trouble, incorporates the knowledge of the power system designers for Space Station Freedom. Trouble is designed to be a ground-based advisor for the mission controllers in the Control Center Complex at Johnson Space Center (JSC). It has been developed at NASA Lewis Research Center (LeRC) and tested in conjunction with prototype flight hardware contained in the Power Management and Distribution testbed and the Engineering Support Center, ESC, at LeRC. Our work will culminate with the adoption of these techniques by the mission controllers at JSC. This paper elucidates how we have captured power system failure knowledge, how we have built and tested our expert system, and what we believe are its potential uses.

Manner, David B.↗

Reducing the cognitive workload - Trouble managing power systems

The complexity of space-based systems makes monitoring them and diagnosing their faults taxing for human beings. When a problem arises, immediate attention and quick resolution is mandatory. To aid humans in these endeavors we have developed an automated advisory system. Our advisory expert system, Trouble, incorporates the knowledge of the power system designers for Space Station Freedom. Trouble is designed to be a ground-based advisor for the mission controllers in the Control Center Complex at Johnson Space Center (JSC). It has been developed at NASA Lewis Research Center (LeRC) and tested in conjunction with prototype flight hardware contained in the Power Management and Distribution testbed and the Engineering Support Center, ESC, at LeRC. Our work will culminate with the adoption of these techniques by the mission controllers at JSC. This paper elucidates how we have captured power system failure knowledge, how we have built and tested our expert system, and what we believe its potential uses are.

Manner, David B.↗

Control System Architectures, Technologies and Concepts for Near Term and Future Human Exploration of Space

Technologies that facilitate the design and control of complex, hybrid, and resource-constrained systems are examined. This paper focuses on design methodologies, and system architectures, not on specific control methods that may be applied to life support subsystems. Honeywell and Boeing have estimated that 60-80Y0 of the effort in developing complex control systems is software development, and only 20-40% is control system development. It has also been shown that large software projects have failure rates of as high as 50-65%. Concepts discussed include the Unified Modeling Language (UML) and design patterns with the goal of creating a self-improving, self-documenting system design process. Successful architectures for control must not only facilitate hardware to software integration, but must also reconcile continuously changing software with much less frequently changing hardware. These architectures rely on software modules or components to facilitate change. Architecting such systems for change leverages the interfaces between these modules or components.

Boulanger, Richard↗