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This presentation reviews the requirements for safety critical fasteners in spaceflight hardware. Included in the presentation are design guidelines and information for Locking Helicoils, key locked inserts and thinwalled inserts, self locking screws and bolts. locknuts, and a locking adhesives, Loctite and Vibratite.
That space is a hazardous environment for humans is common knowledge. Even beyond the obvious lack of air and gravity, the extreme temperatures and exposure to radiation make the human exploration of space a complicated and risky endeavor. The conditions of space and the space suits required to conduct extravehicular activities add layers of difficulty and danger even to tasks that would be simple on Earth (tightening a bolt, for example). For these reasons, the ability to scout distant celestial bodies and perform maintenance and construction in space without direct human involvement offers significant appeal. NASA has repeatedly turned to complex robotics for solutions to extend human presence deep into space at reduced risk and cost and to enhance space operations in low Earth orbit. At Johnson Space Center, engineers explore the potential applications of dexterous robots capable of performing tasks like those of an astronaut during extravehicular activities and even additional ones too delicate or dangerous for human participation. Johnson's Dexterous Robotics Laboratory experiments with a wide spectrum of robot manipulators, such as the Mitsubishi PA-10 and the Robotics Research K-1207i robotic arms. To simplify and enhance the use of these robotic systems, Johnson researchers sought generic control methods that could work effectively across every system.
This slide presentation reviews the effects of corrosion on various structures at the Kennedy Space Center, and the work to discover a corrosion control coating that will be autonomous and will indicate corrosion at an early point in the process. Kennedy Space Center has many environmental conditions that are corrosive: ocean salt spray, heat, humidity, sunlight and acidic exhaust from the Solid Rocket Boosters (SRBs). Presented is a chart which shows the corrosion rates of carbon steel at various locations. KSC has the highest corrosion rates with 42.0 mils/yr, leading the next highest Galeta Point Beach, in the Panama Canal Zone with 27 mils/yr corrosion. A chart shows the changes in corrosion rate with the distance from the ocean. The three types of corrosion protective coatings are described: barrier (passive), Barrier plus active corrosion inhibiting components, and smart. A smart coating will detect and respond actively to changes in its environment in a functional and predictable manner and is capable of adapting its properties dynamically. The smart coating uses microcapsules, particles or liquid drops coated in polymers, that can detect and control the corrosion caused by the environment. The mechanism for a pH sensitive microcapsule and the hydrophobic core microcapsule are demonstrated and the chemistry is reviewed. When corrosion begins, the microcapsule will release the contents of the core (indicator, inhibitor, and self healing agent) in close proximity to the corrosion. The response to a pH increase is demonstrated by a series of pictures that show the breakdown of the microcapsule and the contents release. An example of bolt corrosion is used, as an example of corrosion in places that are difficult to ascertain. A comparison of various coating systems is shown.
This slide presentation reviews the systems engineering process designed to reduce the risk from debris during Space Shuttle Launching. This process begins the day of launch from the tanking to the vehicle tower clearance. Other debris risks (i.e., Ascent, and micrometeoroid orbital debit) are mentioned) but are not the subject of this presentation. The Liftoff debris systems engineering process and an example of how it works are reviewed (i.e.,STS-119 revealed a bolt liberation trend on the Fixed Service Structure (FSS) 275 level elevator room). The process includes preparation of a Certification of Flight Readiness (CoFR) that includes (1) Lift-off debris from previous mission dispositioned, (2) Flight acceptance rationale has been provided for Lift-off debris sources/causes (3) Lift-off debris mission support documentation, processes and tools are in place for the up-coming mission. The process includes a liftoff debris data collection that occurs after each launch. This includes a post launch walkdown, that records each liftoff debris, and the entry of the debris into a database, it also includes a review of the imagery from the launch, and a review of the instrumentation data. There is also a review of the debris transport analysis process, that includes temporal and spatial framework and a computational fluid dynamics (CFD) analysis. which incorporates a debris transport analyses (DTA), debris materials and impact tests, and impact analyses.
A design and analysis of a repair concept applicable to a stiffened thin-skin composite panel based on the Pultruded Rod Stitched Efficient Unitized Structure is presented. Since the repair concept is a bolted repair using metal components, it can easily be applied in the operational environment. Initial analyses are aimed at validating the finite element modeling approach by comparing with available test data. Once confidence in the analysis approach is established several repair configurations are explored and the most efficient one presented. Repairs involving damage to the top of the stiffener alone are considered in addition to repairs involving a damaged stiffener, flange and underlying skin. High fidelity finite element modeling techniques such as mesh-independent definition of compliant fasteners, elastic-plastic metallic material properties and geometrically nonlinear analysis are utilized in the effort. The results of the analysis are presented and factors influencing the design are assessed and discussed.
In recent years, some remote-sensing applications require advanced airborne multi-sensor systems to provide high performance reflective and emissive spectral imaging measurement rapidly over large areas. The key or unique problem of characteristics is associated with a black box back-end system that operates a suite of cutting-edge imaging sensors to collect simultaneously the high throughput reflective and emissive spectral imaging data with precision georeference. This back-end system needs to be portable, easy-to-use, and reliable with advanced onboard processing. The innovation of the black box backend is a miniaturized airborne imaging central server system (MAICSS). MAICSS integrates a complex embedded system of systems with dedicated power and signal electronic circuits inside to serve a suite of configurable cutting-edge electro- optical (EO), long-wave infrared (LWIR), and medium-wave infrared (MWIR) cameras, a hyperspectral imaging scanner, and a GPS and inertial measurement unit (IMU) for atmospheric and surface remote sensing. Its compatible sensor packages include NASA s 1,024 1,024 pixel LWIR quantum well infrared photodetector (QWIP) imager; a 60.5 megapixel BuckEye EO camera; and a fast (e.g. 200+ scanlines/s) and wide swath-width (e.g., 1,920+ pixels) CCD/InGaAs imager-based visible/near infrared reflectance (VNIR) and shortwave infrared (SWIR) imaging spectrometer. MAICSS records continuous precision georeferenced and time-tagged multisensor throughputs to mass storage devices at a high aggregate rate, typically 60 MB/s for its LWIR/EO payload. MAICSS is a complete stand-alone imaging server instrument with an easy-to-use software package for either autonomous data collection or interactive airborne operation. Advanced multisensor data acquisition and onboard processing software features have been implemented for MAICSS. With the onboard processing for real time image development, correction, histogram-equalization, compression, georeference, and data organization, fast aerial imaging applications, including the real time LWIR image mosaic for Google Earth, have been realized for NASA fs LWIR QWIP instrument. MAICSS is a significant improvement and miniaturization of current multisensor technologies. Structurally, it has a complete modular and solid-state design. Without rotating hard drives and other moving parts, it is operational at high altitudes and survivable in high-vibration environments. It is assembled from a suite of miniaturized, precision-machined, standardized, and stackable interchangeable embedded instrument modules. These stackable modules can be bolted together with the interconnection wires inside for the maximal simplicity and portability. Multiple modules are electronically interconnected as stacked. Alternatively, these dedicated modules can be flexibly distributed to fit the space constraints of a flying vehicle. As a flexibly configurable system, MAICSS can be tailored to interface a variety of multisensor packages. For example, with a 1,024x1,024 pixel LWIR and a 8,984x6,732 pixel EO payload, the complete MAICSS volume is approximately 7x9x11 in. (=18x23x28 cm), with a weight of 25 lb (=11.4 kg).
This innovation comprises a compact drill that uses low-axial preload, via vibrations, that fractures the rock under the bit kerf, and rotates the bit to remove the powdered cuttings while augmenting the rock fracture via shear forces. The vibrations fluidize the powered cuttings inside the flutes around the bit, reducing the friction with the auger surface. These combined actions reduce the consumed power and the heating of the drilled medium, helping to preserve the pristine content of the produced samples. The drill consists of an actuator that simultaneously impacts and rotates the bit by applying force and torque via a single piezoelectric stack actuator without the need for a gearbox or lever mechanism. This reduces the development/fabrication cost and complexity. The piezoelectric actuator impacts the surface and generates shear forces, fragmenting the drilled medium directly under the bit kerf by exceeding the tensile and/or shear strength of the struck surface. The percussive impact action of the actuator leads to penetration of the medium by producing a zone of finely crushed rock directly underneath the struck location. This fracturing process is highly enhanced by the shear forces from the rotation and twisting action. To remove the formed cuttings, the bit is constructed with an auger on its internal or external surface. One of the problems with pure hammering is that, as the teeth become embedded in the sample, the drilling efficiency drops unless the teeth are moved away from the specific footprint location. By rotating the teeth, they are moved to areas that were not fragmented, and thus the rock fracturing is enhanced via shear forces. The shear motion creates ripping or chiseling action to produce larger fragments to increase the drilling efficiency, and to reduce the required power. The actuator of the drill consists of a piezoelectric stack that vibrates the horn. The stack is compressed by a bolt between the backing and the horn in order to prevent it from being subjected to tensile stress that will cause it to fail. The backing is intended to transfer the generated mechanical vibrations towards the horn. In order to cause rotation, the horn is configured asymmetrically with helical segments and, upon impacting the bit, it introduces longitudinal along the axis of the actuator and tangential force causing twisting action that rotates the bit. The longitudinal component of the vibrations of the stack introduces percussion impulses between the bit and the rock to fracture it when the ultimate strain is exceeded under the bit.
A tool makes it possible to couple a torque wrench to an externally knurled, internally threaded, round cable connector. The purpose served by the tool is to facilitate the tightening of multiple such connectors (or the repeated tightening of the same connector) to repeatable torques. The design of a prior cable-connector/ torque-wrench coupling tool provided for application of the torque-wrench jaws to a location laterally offset from the axis of rotation of the cable connector, making it necessary to correct the torque reading for the offset. Unlike the design of the prior tool, the design of the present tool provides for application of the torque-wrench jaws to a location on the axis of rotation, obviating correction of the torque reading for offset. The present tool (see figure) consists of a split collet containing a slot that provides clearance for inserting and bending the cable, a collet-locking sleeve, a collet-locking nut, and a torque-wrench adaptor that is press-fit onto the collet. Once the collet is positioned on the cable connector, the collet-locking nut is turned to force the collet-locking sleeve over the collet, compressing the collet through engagement of tapered surfaces on the outside of the collet and the inside of the locking sleeve. Because the collet is split and therefore somewhat flexible, this compression forces the collet inward to grip the connector securely. The torque wrench is then applied to the torque-wrench adaptor in the usual manner for torquing a nut or a bolt.
A report describes the main features of a system for testing pyrotechnic and mechanical devices used to separate spacecraft and modules of spacecraft during flight. The system includes a spacecraft simulator [also denoted a large mobility base (LMB)] equipped with air thrusters, sensors, and data-acquisition equipment. The spacecraft simulator floats on air bearings over an epoxy-covered concrete floor. This free-flotation arrangement enables simulation of motion in outer space in three degrees of freedom: translation along two orthogonal horizontal axes and rotation about a vertical axis. The system also includes a static stand. In one application, the system was used to test a bolt-retraction system (BRS) intended for separation of the lifting-body and deorbit-propulsion stages of the X- 38 spacecraft. The LMB was connected via the BRS to the static stand, then pyrotechnic devices that actuate the BRS were fired. The separation distance and acceleration were measured. The report cites a document, not yet published at the time of reporting the information for this article, that is said to present additional detailed information.
Topics covered include: Fiber-Optic Sensor Would Monitor Growth of Polymer Film; Sensors for Pointing Moving Instruments Toward Each Other; Pd/CeO2/SiC Chemical Sensors; Microparticle Flow Sensor; Scattering-Type Surface-Plasmon-Resonance Biosensors; Diode-Laser-Based Spectrometer for Sensing Gases; Improved Cathode Structure for a Direct Methanol Fuel Cell; X-Band, 17-Watt Solid-State Power Amplifier; Improved Anode for a Direct Methanol Fuel Cell; Tools for Designing and Analyzing Structures; Interactive Display of Scenes with Annotations; Solving Common Mathematical Problems; Tools for Basic Statistical Analysis; Program Calculates Forces in Bolted Structural Joints; Integrated Structural Analysis and Test Program; Molybdate Coatings for Protecting Aluminum Against Corrosion; Synthesizing Diamond from Liquid Feedstock; Modifying Silicates for Better Dispersion in Nanocomposites; Powder-Collection System for Ultrasonic/Sonic Drill/Corer; Semiautomated, Reproducible Batch Processing of Soy; Hydrogen Peroxide Enhances Removal of NOx from Flue Gases; Subsurface Ice Probe; Real-Time Simulation of Aeroheating of the Hyper-X Airplane; Using Laser-Induced Incandescence To Measure Soot in Exhaust; Method of Real-Time Principal-Component Analysis; Insect-Inspired Flight Control for Unmanned Aerial Vehicles; Domain Compilation for Embedded Real-Time Planning; Semantic Metrics for Analysis of Software; Simulation of Laser Cooling and Trapping in Engineering Applications; Large Fluvial Fans and Exploration for Hydrocarbons; Doping-Induced Interband Gain in InAs/AlSb Quantum Wells; Development of Software for a Lidar-Altimeter Processor; Upgrading the Space Shuttle Caution and Warning System; and Fractal Reference Signals in Pulse-Width Modulation.
The Fastener Starter is a creative solution to prevent the loss of small fasteners during their installation. This is the only currently available tool that can firmly grip and hold a single screw, bolt, nut, washer, spacer, or any combination of these parts. Other commercially available fastener starters are unable to accommodate a variety of parts simultaneously. The Fastener Starter is a more capable and easier tool to use than prior tools. Its compact size allows it to be used effectively in cramped, difficult-to-see locations. Its design also allows it to be used with or without handles and extenders in other difficult-to-reach locations. It provides better protection against cross threading and loss of fasteners and associated parts. The Fastener Starter is non-magnetic and does not off-gas, thus meeting flight hardware requirements. The Fastener Starter incorporates a combination of features of several commercially available tools, providing an improved means of installing small fasteners. The Fastener Starter includes a custom molded insert that can be removed easily and replaced with a conventional tool bit (e.g., a screwdriver or hex-driver bit). When used with the insert, the Fastener Starter prevents cross threading and damage to internal threaded holes. This is achieved by allowing the fastener to slip within the tool insert when used without a conventional tool bit. Alternatively, without the insert and with a tool bit, the Fastener Starter can torque a fastener. The Fastener Starter has a square recess hole that accepts a conventional square drive handle or extension to accommodate a variety of applications by providing flexibility in handle style and length.
A report describes the development of a mechanism that automatically clamps upon warming and releases upon cooling between temperature limits of approx. =180 K and approx. =293 K. The mechanism satisfied a need specific to a program that involved repeated excursions of a spectrometer between a room-temperature atmospheric environment and a cryogenic vacuum testing environment. The mechanism was also to be utilized in the intended application of the spectrometer, in which the spectrometer would be clamped for protection during launch of a spacecraft and released in the cold of outer space to allow it to assume its nominal configuration for scientific observations. The mechanism is passive in the sense that its operation does not depend on a control system and does not require any power other than that incidental to heating and cooling. The clamping and releasing action is effected by bolt-preloaded stacks of shape-memory-alloy (SMA) cylinders. In designing this mechanism, as in designing other, similar SMA mechanisms, it was necessary to account for the complex interplay among thermal expansion, elastic and inelastic deformation under load, and SMA thermomechanical properties.
Vacuum apparatuses have been developed for increasing the range of elements that can be identified by use of x-ray fluorescent (XRF) scanners of the type mentioned in the two immediately preceding articles. As a consequence of the underlying physical principles, in the presence of air, such an XRF scanner is limited to analysis of chlorine and elements of greater atomic number. When the XRF scanner is operated in a vacuum, it extends the range of analysis to lower atomic numbers - even as far as aluminum and sodium. Hence, more elements will be available for use in XRF labeling of objects as discussed in the two preceding articles. The added benefits of the extended capabilities also have other uses for NASA. Detection of elements of low atomic number is of high interest to the aerospace community. High-strength aluminum alloys will be easily analyzed for composition. Silicon, a major contaminant in certain processes, will be detectable before the process is begun, possibly eliminating weld or adhesion problems. Exotic alloys will be evaluated for composition prior to being placed in service where lives depend on them. And in the less glamorous applications, such as bolts and fasteners, substandard products and counterfeit items will be evaluated at the receiving function and never allowed to enter the operation
The multistage electromagnetic separator for purifying cells and magnetic particles (MAGSEP) is a laboratory apparatus for separating and/or purifying particles (especially biological cells) on the basis of their magnetic susceptibility and magnetophoretic mobility. Whereas a typical prior apparatus based on similar principles offers only a single stage of separation, the MAGSEP, as its full name indicates, offers multiple stages of separation; this makes it possible to refine a sample population of particles to a higher level of purity or to categorize multiple portions of the sample on the basis of magnetic susceptibility and/or magnetophoretic mobility. The MAGSEP includes a processing unit and an electronic unit coupled to a personal computer. The processing unit includes upper and lower plates, a plate-rotation system, an electromagnet, an electromagnet-translation system, and a capture-magnet assembly. The plates are bolted together through a roller bearing that allows the plates to rotate with respect to each other. An interface between the plates acts as a seal for separating fluids. A lower cuvette can be aligned with as many as 15 upper cuvette stations for fraction collection during processing. A two-phase stepping motor drives the rotation system, causing the upper plate to rotate for the collection of each fraction of the sample material. The electromagnet generates a magnetic field across the lower cuvette, while the translation system translates the electromagnet upward along the lower cuvette. The current supplied to the electromagnet, and thus the magnetic flux density at the pole face of the electromagnet, can be set at a programmed value between 0 and 1,400 gauss (0.14 T). The rate of translation can be programmed between 5 and 2,000 m/s so as to align all sample particles in the same position in the cuvette. The capture magnet can be a permanent magnet. It is mounted on an arm connected to a stepping motor. The stepping motor rotates the arm to position the capture magnet above the upper cuvette into which a fraction of the sample is collected. The electronic unit includes a power switch, power-supply circuitry that accepts 110-Vac input power, an RS-232 interface, and status lights. The personal computer runs the MAGSEP software and controls the operation of the MAGSEP through the RS-232 interface. The status of the power, the translating electromagnet, the capture magnet, and the rotation of the upper plate are indicated in a graphical user interface on the computer screen.
A proposed thermal-bonding technique would make it possible to join or separate thermoplastic parts quickly and efficiently. The technique would eliminate the need for conventional welding or for such conventional fastening components as bolted flanges or interlocking hooks. The technique could be particularly useful in the sign industry (in which large quantities of thermoplastics are used) or could be used to join plastic pipes. A thin sheet of a suitable electrically conductive material would be formed to fit between two thermoplastic parts to be joined (see figure). The electrically conductive sheet and the two parts would be put together tightly, then an electrical current would be sent through the conductor to heat the thermoplastic locally. The magnitude of the current and the heating time would be chosen to generate just enough heat to cause the thermoplastic to adhere to both sides of the electrically conductive sheet. Optionally, the electrically conductive sheet could contain many small holes to provide purchase or to increase electrical resistance to facilitate the generation of heat. After thermal bonding, the electrically conductive sheet remains as an integral part of the structure. If necessary, the electrically conductive sheet can be reheated later to separate the joined thermoplastic parts.
Topics covered include: Brazing SiC/SiC Composites to Metals; Composite-Material Tanks with Chemically Resistant Liners; Thermally Conductive Metal-Tube/Carbon-Composite Joints; Improved BN Coatings on SiC Fibers in SiC Matrices; Iterative Demodulation and Decoding of Non-Square QAM; Measuring Radiation Patterns of Reconfigurable Patch Antennas on Wafers; Low-Cutoff, High-Pass Digital Filtering of Neural Signals; Further Improvement in 3DGRAPE; Ground Support Software for Spaceborne Instrumentation; MER SPICE Interface; Simulating Operation of a Planetary Rover; Analyzing Contents of a Computer Cache; Discrepancy Reporting Management System; Silicone-Rubber Microvalves Actuated by Paraffin; Hydraulic Apparatus for Mechanical Testing of Nuts; Heat Control via Torque Control in Friction Stir Welding; Manufacturing High-Quality Carbon Nanotubes at Lower Cost; Setup for Visual Observation of Carbon-Nanotube Arc Process; Solution Preserves Nucleic Acids in Body-Fluid Specimens; Oligodeoxynucleotide Probes for Detecting Intact Cells; Microwave-Spectral Signatures Would Reveal Concealed Objects; Digital Averaging Phasemeter for Heterodyne Interferometry; Optoelectronic Instrument Monitors pH in a Culture Medium; Imaging of gamma-Irradiated Regions of a Crystal; Photodiode-Based, Passive Ultraviolet Dosimeters; Discrete Wavelength-Locked External Cavity Laser; Flexible Shields for Protecting Spacecraft Against Debris; Part 2 of a Computational Study of a Drop-Laden Mixing Layer; Controllable Curved Mirrors Made from Single-Layer EAP Films; and Demonstration of a Pyrotechnic Bolt-Retractor System.
Human-robot interaction (HRI) is about understanding and shaping the interactions between humans and robots (Goodrich & Schultz, 2007). It is important to evaluate how the design of interfaces and command modalities affect the human s ability to perform tasks accurately, efficiently, and effectively (Crandall, Goodrich, Olsen Jr., & Nielsen, 2005) It is also critical to evaluate the effects of human-robot interfaces and command modalities on operator mental workload (Sheridan, 1992) and situation awareness (Endsley, Bolt , & Jones, 2003). By understanding the effects of interface design on human performance, workload, and situation awareness, interfaces can be developed that support the human in performing tasks with minimal errors and with appropriate interaction time and effort. Thus, the results of research on human-robot interfaces have direct implications for design. Because the factors associated with interfaces and command modalities in HRI are too numerous to address in 3 years of research, the proposed research concentrates on three manageable areas applicable to National Aeronautics and Space Administration (NASA) robot systems. These topic areas emerged from the Fiscal Year (FY) 2011 work that included extensive literature reviews and observations of NASA systems. The three topic areas are: 1) video overlays, 2) camera views, and 3) command modalities. Each area is described in detail below, along with relevance to existing NASA human-robot systems. In addition to studies in these three topic areas, a workshop is proposed for FY12. The workshop will bring together experts in human-robot interaction and robotics to discuss the state of the practice as applicable to research in space robotics. Studies proposed in the area of video overlays consider two factors in the implementation of augmented reality (AR) for operator displays during teleoperation. The first of these factors is the type of navigational guidance provided by AR symbology. In the proposed studies, participants performance during teleoperation of a robot arm will be compared when they are provided with command-guidance symbology (that is, directing the operator what commands to make) or situation-guidance symbology (that is, providing natural cues so that the operator can infer what commands to make). The second factor for AR symbology is the effects of overlays that are either superimposed or integrated into the external view of the world. A study is proposed in which the effects of superimposed and integrated overlays on operator task performance during teleoperated driving tasks are compared
A simple, effective, easy-to-use device locks a control knob in a set position. In the initial application for which this device was conceived, the control knob to be locked is that of a needle valve. Previously, in that application, it was necessary for one technician to hold the knob to keep the valve at the desired flow setting while another technician secured the valve with safety wire -- a time-consuming procedure. After attachment of the wire, it was still possible to turn the knob somewhat. In contrast, a single technician using the present device can secure the knob in the desired position. in about 30 seconds, and the knob cannot thereafter be turned, even in the presence of harsh vibrations, which occur during space shuttle launch. The device includes a special-purpose clamp that fits around the control knob and its shaft and that can be tightened onto the knob, without turning the knob, by means of two thumbscrews. The end of the device opposite the clamp is a tang that contains a slot that, in turn, engages a bolt that protrudes from the panel on which the control knob and its shaft are mounted.