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NASA NTRS2008

Development of a Spacecraft Antenna Pointing Gimbal

The development of the pointing gimbal in the high-gain antenna system (HGAS) of the Solar Dynamics Observatory spacecraft is described. The gimbal was designed for 5 years of service in Geo-Synchronous orbit. The hardware incorporates multiple levels of redundancy, allows harnessing and waveguide along its full length across its two axes of rotation and points with an accuracy of better than 0.065 . Significant issues with actuator alignment, Electrical Contact Ring noise, pointing budget, and waveguide failures are described, along with their respective resolutions

Monroe, Charles↗

NASA NTRS2014

Cutting More than Metal: Breaking the Development Cycle

New technology is changing the way we do business at NASA. The ability to use these new tools is made possible by a learning culture able to embrace innovation, flexibility, and prudent risk tolerance, while retaining the hard-won lessons learned of other successes and failures. Technologies such as 3-D manufacturing and structured light scanning are re-shaping the entire product life cycle, from design and analysis, through production, verification, logistics and operations. New fabrication techniques, verification techniques, integrated analysis, and models that follow the hardware from initial concept through operation are reducing the cost and time of building space hardware. Using these technologies to be more efficient, reliable and affordable requires we bring them to a level safe for NASA systems, maintain appropriate rigor in testing and acceptance, and transition new technology. Maximizing these technologies also requires cultural acceptance and understanding and balancing rules with creativity. Evolved systems engineering processes at NASA are increasingly more flexible than they have been in the past, enabling the implementation of new techniques and approaches. This paper provides an overview of NASA Marshall Space Flight Center's new approach to development, as well as examples of how that approach has been incorporated into NASA's Space Launch System (SLS) Program, which counts among its key tenants - safety, affordability, and sustainability. One of the 3D technologies that will be discussed in this paper is the design and testing of various rocket engine components.

Singer, Chris↗

NASA NTRS2014

Can Cell to Cell Thermal Runaway Propagation be Prevented in a Li-ion Battery Module?

Increasing cell spacing decreased adjacent cell damage center dotElectrically connected adjacent cells drained more than physically adjacent cells center dotRadiant barrier prevents propagation when fully installed between BP cells center dotBP cells vent rapidly and expel contents at 100% SOC -Slower vent with flame/smoke at 50% -Thermal runaway event typically occurs at 160 degC center dotLG cells vent but do not expel contents -Thermal runaway event typically occurs at 200 degC center dotSKC LFP modules did not propagate; fuses on negative terminal of cell may provide a benefit in reducing cell to cell damage propagation. New requirement in NASA-Battery Safety Requirements document: JSC 20793 Rev C 5.1.5.1 Requirements - Thermal Runaway Propagation a. For battery designs greater than a 80-Wh energy employing high specific energy cells (greater than 80 watt-hours/kg, for example, lithium-ion chemistries) with catastrophic failure modes, the battery shall be evaluated to ascertain the severity of a worst-case single-cell thermal runaway event and the propensity of the design to demonstrate cell-to-cell propagation in the intended application and environment. NASA has traditionally addressed the threat of thermal runaway incidents in its battery deployments through comprehensive prevention protocols. This prevention-centered approach has included extensive screening for manufacturing defects, as well as robust battery management controls that prevent abuse-induced runaway even in the face of multiple system failures. This focused strategy has made the likelihood of occurrence of such an event highly improbable. b. The evaluation shall include all necessary analysis and test to quantify the severity (consequence) of the event in the intended application and environment as well as to identify design modifications to the battery or the system that could appreciably reduce that severity. In addition to prevention protocols, programs developing battery designs with catastrophic failure modes should take the steps necessary to assess the severity of a possible thermal runaway event. Programs should assess whether there are reasonable design changes that could appreciably affect the severity of the outcome. Evaluation should include environmental effects to surrounding hardware (i.e., temperature, pressure, shock), contamination effects due to any expelled contaminates, and venting propulsive effects when venting overboard.

Jeevarajan, Judith↗

NASA NTRS2018

Use of Shuttle Heritage Hardware in Space Launch System (SLS) Application-Structural Assessment

NASA is moving forward with the development of the next generation system of human spaceflight to meet the Nation's goals of human space exploration. To meet these goals, NASA is aggressively pursuing the development of an integrated architecture and capabilities for safe crewed and cargo missions beyond low-Earth orbit. Two important tenets critical to the achievement of NASA's strategic objectives are Affordability and Safety. The Space Launch System (SLS) is a heavy-lift launch vehicle being designed/developed to meet these goals. The SLS Block 1 configuration (Figure 1) will be used for the first Exploration Mission (EM-1). It utilizes existing hardware from the Space Shuttle inventory, as much as possible, to save cost and expedite the schedule. SLS Block 1 Elements include the Core Stage, "Heritage" Boosters, Heritage Engines, and the Integrated Spacecraft and Payload Element (ISPE) consisting of the Launch Vehicle Stage Adapter (LVSA), the Multi-Purpose Crew Vehicle (MPCV) Stage Adapter (MSA), and an Interim Cryogenic Propulsion Stage (ICPS) for Earth orbit escape and beyond-Earth orbit in-space propulsive maneuvers. When heritage hardware is used in a new application, it requires a systematic evaluation of its qualification. In addition, there are previously-documented Lessons Learned (Table -1) in this area cautioning the need of a rigorous evaluation in any new application. This paper will exemplify the systematic qualification/assessment efforts made to qualify the application of Heritage Solid Rocket Booster (SRB) hardware in SLS. This paper describes the testing and structural assessment performed to ensure the application is acceptable for intended use without having any adverse impact to Safety. It will further address elements such as Loads, Material Properties and Manufacturing, Testing, Analysis, Failure Criterion and Factor of Safety (FS) considerations made to reach the conclusion and recommendation.

Aggarwal, Pravin↗

NASA NTRSDate not supplied

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 medical transportation in major metropolitan areas. This will be accomplished with distributed electric powered vertical takeoff and landing aircraft vehicles. The low specific energy of the current generation lithium-ion battery packs limit the operational range of the electric aircraft. Limited range impacts safety by reducing the amount of time available for analyzing the potential impact of errors and failures and responding to them, and for flying to an alternative landing area or returning to the base. It is therefore critical to understand the impact of flight and environmental conditions on the onboard lithium-ion battery pack’s health. With this as the motivation, the procedure for evaluating the performance of battery packs in a laboratory setting and the results obtained using this procedure on battery packs subject to power draw characteristics of a simulated flight of a NASA conceptual quadrotor aircraft model are described. The fully charged battery is allowed to discharge at specific C-rates based on the power draw profile during the experiment, and the current and voltages are recorded as a function of time. Observed results under different operating conditions and mission profiles are discussed.

UAM↗

NASA NTRS2000

A Nuclear Interaction Model for Understanding Results of Single Event Testing with High Energy Protons

An internuclear cascade and evaporation model has been adapted to estimate the LET spectrum generated during testing with 200 MeV protons. The model-generated heavy ion LET spectrum is compared to the heavy ion LET spectrum seen on orbit. This comparison is the basis for predicting single event failure rates from heavy ions using results from a single proton test. Of equal importance, this spectra comparison also establishes an estimate of the risk of encountering a failure mode on orbit that was not detected during proton testing. Verification of the general results of the model is presented based on experiments, individual part test results, and flight data. Acceptance of this model and its estimate of remaining risk opens the hardware verification philosophy to the consideration of radiation testing with high energy protons at the board and box level instead of the more standard method of individual part testing with low energy heavy ions.

Culpepper, William X.↗

NASA NTRS2009

Developing Sustainable Spacecraft Water Management Systems

It is well recognized that water handling systems used in a spacecraft are prone to failure caused by biofouling and mineral scaling, which can clog mechanical systems and degrade the performance of capillary-based technologies. Long duration spaceflight applications, such as extended stays at a Lunar Outpost or during a Mars transit mission, will increasingly benefit from hardware that is generally more robust and operationally sustainable overtime. This paper presents potential design and testing considerations for improving the reliability of water handling technologies for exploration spacecraft. Our application of interest is to devise a spacecraft wastewater management system wherein fouling can be accommodated by design attributes of the management hardware, rather than implementing some means of preventing its occurrence.

Thomas, Evan A.↗

NASA NTRS2011

Reusable Solid Rocket Motor - Accomplishments, Lessons, and a Culture of Success

The Reusable Solid Rocket Motor represents the largest solid rocket motor ever flown and the only human rated solid motor. Each Reusable Solid Rocket Motor (RSRM) provides approximately 3-million lb of thrust to lift the integrated Space Shuttle vehicle from the launch pad. The motors burn out approximately 2 minutes later, separate from the vehicle and are recovered and refurbished. The size of the motor and the need for high reliability were challenges. Thrust shaping, via shaping of the propellant grain, was needed to limit structural loads during ascent. The motor design evolved through several block upgrades to increase performance and to increase safety and reliability. A major redesign occurred after STS-51L with the Redesigned Solid Rocket Motor. Significant improvements in the joint sealing systems were added. Design improvements continued throughout the Program via block changes with a number of innovations including development of low temperature o-ring materials and incorporation of a unique carbon fiber rope thermal barrier material. Recovery of the motors and post flight inspection improved understanding of hardware performance, and led to key design improvements. Because of the multidecade program duration material obsolescence was addressed, and requalification of materials and vendors was sometimes needed. Thermal protection systems and ablatives were used to protect the motor cases and nozzle structures. Significant understanding of design and manufacturing features of the ablatives was developed during the program resulting in optimization of design features and processing parameters. The project advanced technology in eliminating ozone-depleting materials in manufacturing processes and the development of an asbestos-free case insulation. Manufacturing processes for the large motor components were unique and safety in the manufacturing environment was a special concern. Transportation and handling approaches were also needed for the large hardware segments. The reusable solid rocket motor achieved significant reliability via process control, ground test programs, and postflight assessment. Process control is mandatory for a solid rocket motor as an acceptance test of the delivered product is not feasible. Process control included process failure modes and effects analysis, statistical process control, witness panels, and process product integrity audits. Material controls and inspections were maintained throughout the sub tier vendors. Material fingerprinting was employed to assess any drift in delivered material properties. The RSRM maintained both full scale and sub-scale test articles. These enabled continuous improvement of design and evaluation of process control and material behavior. Additionally RSRM reliability was achieved through attention to detail in post flight assessment to observe any shift in performance. The postflight analysis and inspections provided invaluable reliability data as it enables observation of actual flight performance, most of which would not be available if the motors were not recovered. These unique challenges, features of the reusable solid rocket motor, materials and manufacturing issues, and design improvements will be discussed in the paper.

Moore, Dennis R.↗

NASA NTRS1992

Implementation of an intelligent control system

A laboratory testbed facility which was constructed at NASA LeRC for the development of an Intelligent Control System (ICS) for reusable rocket engines is described. The framework of the ICS consists of a hierarchy of various control and diagnostic functions. The traditional high speed, closed-loop controller resides at the lowest level of the ICS hierarchy. Above this level resides the diagnostic functions which identify engine faults. The ICS top level consists of the coordination function which manages the interaction between an expert system and a traditional control system. The purpose of the testbed is to demonstrate the feasibility of the OCS concept by implementing the ICS as the primary controller in a simulation of the Space Shuttle Main Engine (SSME). The functions of the ICS which are implemented in the testbed are as follows: an SSME dynamic simulation with selected fault mode models, a reconfigurable controller, a neural network for sensor validation, a model-based failure detection algorithm, a rule based failure detection algorithm, a diagnostic expert system, an intelligent coordinator, and a user interface which provides a graphical representation of the event occurring within the testbed. The diverse nature of the ICS has led to the development of a distributed architecture consisting of specialized hardware and software for the implementation of the various functions. This testbed is made up of five different computer systems. These individual computers are discussed along with the schemes used to implement the various ICS components. The communication between computers and the timing and synchronization between components are also addressed.

Simon, D. L.↗

NASA NTRS1993

Advanced Information Processing System (AIPS)

Advanced Information Processing System (AIPS) is a computer systems philosophy, a set of validated hardware building blocks, and a set of validated services as embodied in system software. The goal of AIPS is to provide the knowledgebase which will allow achievement of validated fault-tolerant distributed computer system architectures, suitable for a broad range of applications, having failure probability requirements of 10E-9 at 10 hours. A background and description is given followed by program accomplishments, the current focus, applications, technology transfer, FY92 accomplishments, and funding.

Pitts, Felix L.↗

NASA NTRS1999

Backup Attitude Control Algorithms for the MAP Spacecraft

The Microwave Anisotropy Probe (MAP) is a follow-on to the Differential Microwave Radiometer (DMR) instrument on the Cosmic Background Explorer (COBE) spacecraft. The MAP spacecraft will perform its mission, studying the early origins of the universe, in a Lissajous orbit around the Earth-Sun L(sub 2) Lagrange point. Due to limited mass, power, and financial resources, a traditional reliability concept involving fully redundant components was not feasible. This paper will discuss the redundancy philosophy used on MAP, describe the hardware redundancy selected (and why), and present backup modes and algorithms that were designed in lieu of additional attitude control hardware redundancy to improve the odds of mission success. Three of these modes have been implemented in the spacecraft flight software. The first onboard mode allows the MAP Kalman filter to be used with digital sun sensor (DSS) derived rates, in case of the failure of one of MAP's two two-axis inertial reference units. Similarly, the second onboard mode allows a star tracker only mode, using attitude and derived rate from one or both of MAP's star trackers for onboard attitude determination and control. The last backup mode onboard allows a sun-line angle offset to be commanded that will allow solar radiation pressure to be used for momentum management and orbit stationkeeping. In addition to the backup modes implemented on the spacecraft, two backup algorithms have been developed in the event of less likely contingencies. One of these is an algorithm for implementing an alternative scan pattern to MAP's nominal dual-spin science mode using only one or two reaction wheels and thrusters. Finally, an algorithm has been developed that uses thruster one shots while in science mode for momentum management. This algorithm has been developed in case system momentum builds up faster than anticipated, to allow adequate momentum management while minimizing interruptions to science. In this paper, each mode and algorithm will be discussed, and simulation results presented.

ODonnell, James R., Jr.↗

NASA NTRS2013

Design of Test Support Hardware for Advanced Space Suits

As a member of the Space Suit Assembly Development Engineering Team, I designed and built test equipment systems to support the development of the next generation of advanced space suits. During space suit testing it is critical to supply the subject with two functions: (1) cooling to remove metabolic heat, and (2) breathing air to pressurize the space suit. The objective of my first project was to design, build, and certify an improved Space Suit Cooling System for manned testing in a 1‐G environment. This design had to be portable and supply a minimum cooling rate of 2500 BTU/hr. The Space Suit Cooling System is a robust, portable system that supports very high metabolic rates. It has a highly adjustable cool rate and is equipped with digital instrumentation to monitor the flowrate and critical temperatures. It can supply a variable water temperature down to 34 deg., and it can generate a maximum water flowrate of 2.5 LPM. My next project was to design and build a Breathing Air System that was capable of supply facility air to subjects wearing the Z‐2 space suit. The system intakes 150 PSIG breathing air and regulates it to two operating pressures: 4.3 and 8.3 PSIG. It can also provide structural capabilities at 1.5x operating pressure: 6.6 and 13.2 PSIG, respectively. It has instrumentation to monitor flowrate, as well as inlet and outlet pressures. The system has a series of relief valves to fully protect itself in case of regulator failure. Both projects followed a similar design methodology. The first task was to perform research on existing concepts to develop a sufficient background knowledge. Then mathematical models were developed to size components and simulate system performance. Next, mechanical and electrical schematics were generated and presented at Design Reviews. After the systems were approved by the suit team, all the hardware components were specified and procured. The systems were then packaged, fabricated, and thoroughly tested. The next step was to certify the equipment for manned used, which included generating a Hazard Analysis and giving a presentation to the Test Readiness Review Board. Both of these test support systems will perform critical roles in the development of next‐generation space suits. They will used on a regular basis to test the NASA's new Z‐2 Space Suit. The Space Suit Cooling System is now the primary cooling system for all advanced suit tests.

Watters, Jeffrey A.↗

NASA NTRS1993

WTEC monograph on instrumentation, control and safety systems of Canadian nuclear facilities

This report updates a 1989-90 survey of advanced instrumentation and controls (I&C) technologies and associated human factors issues in the U.S. and Canadian nuclear industries carried out by a team from Oak Ridge National Laboratory (Carter and Uhrig 1990). The authors found that the most advanced I&C systems are in the Canadian CANDU plants, where the newest plant (Darlington) has digital systems in almost 100 percent of its control systems and in over 70 percent of its plant protection system. Increased emphasis on human factors and cognitive science in modern control rooms has resulted in a reduced workload for the operators and the elimination of many human errors. Automation implemented through digital instrumentation and control is effectively changing the role of the operator to that of a systems manager. The hypothesis that properly introducing digital systems increases safety is supported by the Canadian experience. The performance of these digital systems has been achieved using appropriate quality assurance programs for both hardware and software development. Recent regulatory authority review of the development of safety-critical software has resulted in the creation of isolated software modules with well defined interfaces and more formal structure in the software generation. The ability of digital systems to detect impending failures and initiate a fail-safe action is a significant safety issue that should be of special interest to nuclear utilities and regulatory authorities around the world.

Uhrig, Robert E.↗

NASA NTRS2001

A Two-Wheel Observing Mode for the MAP Spacecraft

The Microwave Anisotropy Probe (MAP) is a follow-on to the Differential Microwave Radiometer (DMR) instrument on the Cosmic Background Explorer (COBE). Due to the MAP project's limited mass, power, and budget, a traditional reliability concept including fully redundant components was not feasible. The MAP design employs selective hardware redundancy, along with backup software modes and algorithms, to improve the odds of mission success. This paper describes the effort to develop a backup control mode, known as Observing II, that will allow the MAP science mission to continue in the event of a failure of one of its three reaction wheel assemblies. This backup science mode requires a change from MAP's nominal zero-momentum control system to a momentum-bias system. In this system, existing thruster-based control modes are used to establish a momentum bias about the sun line sufficient to spin the spacecraft up to the desired scan rate. Natural spacecraft dynamics exhibits spin and nutation similar to the nominal MAP science mode with different relative rotation rates, so the two reaction wheels are used to establish and maintain the desired nutation angle from the sun line. Detailed descriptions of the ObservingII control algorithm and simulation results will be presented, along with the operational considerations of performing the rest of MAP's necessary functions with only two wheels.

Starin, Scott R.↗

NASA NTRS2005

A Reusable and Adaptable Software Architecture for Embedded Space Flight System: The Core Flight Software System (CFS)

The contents include the following: High availability. Hardware is in harsh environment. Flight processor (constraints) very widely due to power and weight constraints. Software must be remotely modifiable and still operate while changes are being made. Many custom one of kind interfaces for one of a kind missions. Sustaining engineering. Price of failure is high, tens to hundreds of millions of dollars.

Wilmot, Jonathan↗

NASA NTRS2011

International Space Station Passive Thermal Control System Analysis, Top Ten Lessons-Learned

The International Space Station (ISS) has been on-orbit for over 10 years, and there have been numerous technical challenges along the way from design to assembly to on-orbit anomalies and repairs. The Passive Thermal Control System (PTCS) management team has been a key player in successfully dealing with these challenges. The PTCS team performs thermal analysis in support of design and verification, launch and assembly constraints, integration, sustaining engineering, failure response, and model validation. This analysis is a significant body of work and provides a unique opportunity to compile a wealth of real world engineering and analysis knowledge and the corresponding lessons-learned. The analysis lessons encompass the full life cycle of flight hardware from design to on-orbit performance and sustaining engineering. These lessons can provide significant insight for new projects and programs. Key areas to be presented include thermal model fidelity, verification methods, analysis uncertainty, and operations support.

Iovine, John↗

NASA NTRS2018

International Space Station Passive Thermal Control System Top Ten Lessons-Learned

Final document not an Abstract attached. The International Space Station (ISS) has been on-orbit for nearly 20 years, and there have been numerous technical challenges along the way from design to assembly to on-orbit anomalies and repairs. The Passive Thermal Control System (PTCS) management team has been a key player in successfully dealing with these challenges. The PTCS team performs thermal analysis in support of design and verification, launch and assembly constraints, integration, sustaining engineering, failure response, and model validation. This analysis is a significant body of work and provides a unique opportunity to compile a wealth of real world engineering and analysis knowledge and the corresponding lessons-learned. The PTCS lessons encompass the full life cycle of flight hardware from design to on-orbit performance and sustaining engineering. These lessons can provide significant insight for new projects and programs. Key areas to be presented include thermal model fidelity, verification methods, analysis uncertainty, and operations support.

Iovine, John V.↗

NASA NTRS2018

International Space Station Passive Thermal Control System Top Ten Lessons-Learned

Iovine, John V.↗