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All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Miniature Exercise Device-2 (MED-2): Preliminary ISS Evaluation Results for a Compact Motorized Resistive and Aerobic Rowing Exercise Device

Future human missions beyond Low Earth Orbit (LEO) will require onboard equipment to provide exercise capabilities for the crew to counter the adverse physiological effects of long-duration microgravity. To accomplish this within the physical constraints of a space vehicle or transit module, a single miniature device that provides both resistive and aerobic exercise modalities is required. To meet this need, Johnson Space Center’s (JSC) Software, Robotics, and Simulation Division (ER) developed the Miniature Exercise Device-2 (MED-2). MED-2 integrates a torque-controlled servomotor and a series-elastic actuator to provide highly-controllable load profiles and a large magnitude output performance in a very small package. This innovative technology is derived from years of JSC/ER design, development and operational experience with cutting-edge robotics, motor controllers, software and actuator/sensor miniaturization, including Robonaut 2 and MED-1. MED-2 was presented at the 2016 ISS R&D Conference. This is an update now that the last of six crewmembers will have completed planned MED-2 sessions on the International Space Station (ISS) in May 2018.Current state-of-the-art ISS exercise equipment consists of two treadmills, a resistive exercise device and two cycle ergometers with a total mass of several thousand pounds and a total volume of several cubic yards. This equipment has proven vital to mitigate the musculoskeletal and cardiovascular degradation effects of microgravity. However, due to the large operational volume and mass of these ISS devices, tailoring them for smaller vehicles, such as Orion, is not possible. In addition, each of the current ISS devices targets a single specific modality. Compared to the existing spaceflight (and even terrestrial) exercise equipment, MED-2 is a new archetype altogether. The combined features of compact size, multi-modality and high-performance is attributable to its innovative series elastic actuator and motor controller. Following its arrival on ISS in 2016, MED-2 was evaluated in two parts. The first and shorter evaluation was an engineering functional checkout of the hardware. As this was a novel exercise device previously never used on ISS, the initial checkout assessed the operation of the hardware and ensured the motion and dynamic range of the crew did not present any collision or other hazards. The second portion of the study collected the heart rates, kinematics and utilized operational volumes of six astronauts to determine the quality of both the resistive and aerobic exercise modalities as delivered by MED-2. Investigators from JSC Biomedical Research and Environmental Science Division (SK) and Glenn Research Center are currently evaluating the data and preparing preliminary results. For the resistive exercise modality, MED-2 demonstrated a range of constant resistive loads from 10-150 lbf. With a displacement range of 84 inches, the MED-2 accommodates users from 5th percentile Japanese female through 95th percentile American male for all of its certified exercises. The displacement measurement accuracy has also been verified within 2.5 percent full range. The crew was able to successfully perform all prescribed resistive exercises, except Goblet Squats which were not feasible with a constant load profile. For the aerobic exercise modality, MED-2 simulated a rowing motion with prescribed and user-selected resistance levels. It has demonstrated rates up to 60 strokes per minute on the ground. MED-2 loads and displacements performance are the same as those cited for the resistive modality. Although each of the crew was able to perform the prescribed aerobic rowing sets, there was considerable variability in the rowing motion among different crewmembers. Also, as expected, the crew was unable to get the full benefits of a typical terrestrial rowing stroke because the current configuration does not allow the user to reach past their feet. These observations have already informed the requirements for other microgravity rowing devices currently in development. One of the unique features of the MED-2 device is the intuitive touch-screen control system. This One Portal graphical user interface (GUI) was developed based on JSC/ER’s heritage knowledge and experience of developing and sustaining the current ISS exercise equipment. Through this interface, the crew easily performed prepared prescriptions as well as had the ability to adjust exercise modality, load and other exercise details such as number of repetitions and number of sets. This touch-screen and GUI fulfilled the MED-2 project goal to simplify the interaction between the user and the device. Furthermore, the extent to which MED-2 utilizes a touchscreen and GUI to control exercise equipment is unmatched among the existing ISS exercise devices. As a motorized device, MED-2 technology can provide a customizable force profile that can be varied as a function of strap displacement, strap velocity or a combination of these and other variables. During 2017, JSC/ER developed and flight-certified a resistive exercise algorithm that mimics the 1-G inertial effects of free-weights and enables adjustable eccentric-to-concentric loading ratios. Subsequent development will explore varying the load profiles and incorporating additional exercises beyond the current list of certified movements.

Exercise↗
NASA NTRS1987

Actuators for a space manipulator

The robotic manipulator can be decomposed into distinct subsytems. One particular area of interest of mechanical subsystems is electromechanical actuators (or drives). A drive is defined as a motor with an appropriate transmission. An overview is given of existing, as well as state-of-the-art drive systems. The scope is limited to space applications. A design philosophy and adequate requirements are the initial steps in designing a space-qualified actuator. The focus is on the d-c motor in conjunction with several types of transmissions (harmonic, tendon, traction, and gear systems). The various transmissions will be evaluated and key performance parameters will be addressed in detail. Included in the assessment is a shuttle RMS joint and a MSFC drive of the Prototype Manipulator Arm. Compound joints are also investigated. Space imposes a set of requirements for designing a high-performance drive assembly. Its inaccessibility and cryogenic conditions warrant special considerations. Some guidelines concerning these conditions are present. The goal is to gain a better understanding in designing a space actuator.

Chun, W.↗
NASA NTRS2001

ISS Flight 2A.2B (STS-106): Commercial Generic Bioprocessing Apparatus (CGBA) Payload BioServe Space Technologies

The two experiments housed in the Commercial Generic Bioprocessing Apparatus (CGBA) during STS-106 were designed to explore how biological processes are affected by microgravity. The first was a developmental study into the effects of microgravity on motor-neuronal growth in the fruit fly species Drosophila melanogaster and the second study was designed to characterize changes in kidney cell gene expression. The objective of the primary experiment, called NIH-B1, was to determine how gravity affects neuronal development of the D. melanogaster embryo and larvae in microgravity, specifically observing the neural connections to muscle fibers.

Stodieck, Louis↗
NASA NTRS1994

Design and performance of the telescope and detector covers on the Extreme Ultraviolet Explorer satellite

Two cover mechanisms were designed and developed for the Extreme Ultraviolet Explorer (EUVE) science payload to keep the EUVE telescope mirrors and detectors sealed from the atmospheric environment until the spacecraft was placed into orbit. There were four telescope front covers and seven motorized detector covers on the EUVE science payload. The EUVE satellite was launched into orbit in June 1992 and all the covers operated successfully after launch. This success can be attributed to high design margins and extensive testing at each level of assembly. This paper described the design of the telescope front covers and the motorized detector covers. This paper also discusses some of the many design considerations and modifications made as performance and reliability problems became apparent from each phase of testing.

Tom, James L.↗
NASA NTRS2017

X-57 Power and Command System Design

This paper describes the power and command system architecture of the X-57 Maxwell flight demonstrator aircraft. The X-57 is an experimental aircraft designed to demonstrate radically improved aircraft efficiency with a 3.5 times aero-propulsive efficiency gain at a "high-speed cruise" flight condition for comparable general aviation aircraft. These gains are enabled by integrating the design of a new, optimized wing and a new electric propulsion system. As a result, the X-57 vehicle takes advantage of the new capabilities afforded by electric motors as primary propulsors. Integrating new technologies into critical systems in experimental aircraft poses unique challenges that require careful design considerations across the entire vehicle system, such as qualification of new propulsors (motors, in the case of the X-57 aircraft), compatibility of existing systems with a new electric power distribution bus, and instrumentation and monitoring of newly qualified propulsion system devices.

electric propulsion↗
NASA NTRS1996

CFD Analysis of the 24-inch JIRAD Hybrid Rocket Motor

A series of multispecies, multiphase computational fluid dynamics (CFD) analyses of the 24-inch diameter joint government industry industrial research and development (JIRAD) hybrid rocket motor is described. The 24-inch JIRAD hybrid motor operates by injection of liquid oxygen (LOX) into a vaporization plenum chamber upstream of ports in the hydroxyl-terminated polybutadiene (HTPB) solid fuel. The injector spray pattern had a strong influence on combustion stability of the JIRAD motor so a CFD study was initiated to define the injector end flow field under different oxidizer spray patterns and operating conditions. By using CFD to gain a clear picture of the flow field and temperature distribution within the JIRAD motor, it is hoped that the fundamental mechanisms of hybrid combustion instability may be identified and then suppressed by simple alterations to the oxidizer injection parameters such as injection angle and velocity. The simulations in this study were carried out using the General Algorithm for Analysis of Combustion SYstems (GALACSY) multiphase combustion codes. GALACSY consists of a comprehensive set of droplet dynamic submodels (atomization, evaporation, etc.) and a computationally efficient hydrocarbon chemistry package built around a robust Navier-Stokes solver optimized for low Mach number flows. Lagrangian tracking of dispersed particles describes a closely coupled spray phase. The CFD cases described in this paper represent various levels of simplification of the problem. They include: (A) gaseous oxygen with combusting fuel vapor blowing off the walls at various oxidizer injection angles and velocities, (B) gaseous oxygen with combusting fuel vapor blowing off the walls, and (C) liquid oxygen with combusting fuel vapor blowing off the walls. The study used an axisymmetric model and the results indicate that the injector design significantly effects the flow field in the injector end of the motor. Markedly different recirculation patterns are observed in the vaporization chamber as the oxygen velocity and/or spray pattern is varied. The ability of these recirculation patterns to stabilize the diffusion flame above the surface of the solid fuel gives a plausible explanation for the experimentally determined combustion stability characteristics of the JIRAD motor, and suggests how combustion stability can be assured by modifications to the injector design.

Liang, Pak-Yan↗
NASA NTRS1972

Filament-wound graphite/epoxy rocket motor case

The fabrication procedures are described for a filament-wound rocket motor case, approximately 56 cm long x 71 cm diameter, utilizing high tensile strength graphite fibers. The process utilized Fiberite Hy-E-1330B prepreg tape which consists of Courtaulds HTS fibers in a temperature-sensitive epoxy matrix. This fabrication effort, with resultant design, material and process recommendations, substantiates the manufacturing feasibility of graphite/epoxy rocket motor cases in the 56 cm x 71 cm size range.

Humphrey, W. D.↗
NASA NTRSDate not supplied

Select Variables Affecting Thermal System Design of a Liquid-Cooled Stator

NASA Glenn Researchers have endeavored to create a high-power-density, efficient electric motor called the High Efficiency Megawatt Motor (HEMM) with a goal of exceeding 98% efficiency and 1.46 MW of power. These aggressive goals were set because increasing the power density and efficiency of electric machines (motors and generators) is integral to bringing electrified aircraft (EA) to commercial realization. Resistive losses in the stator windings are by far the largest (34%) contributor to this design’s total energy losses. Previous testing of a HEMM-like stator test article (statorette) showed good agreement between measured performance and model predictions. Therefore, a foundation was provided to test other engineering parameters that are encountered when designing an electric machine. Of particular interest are the effects of changes to the thickness of the epoxy from the potting process, changes in the fluid volume/flow path around the end windings, and changes in the viscosity of the cooling fluid on the overall thermal performance of the unit. The impact of those parameters as revealed through a third-generation build, test, and finite element model analysis of a statorette test section is the focus of this paper.

EAP↗
NASA NTRS1986

Thrust imbalance of solid rocket motor pairs on Space Shuttle flights

This analysis extends the investigation presented at the 17th Joint Propulsion Conference in 1981 to include fifteen sets of Space Shuttle flight data. The previous report dealt only with static test data and the first flight pair. The objective is to compare the authors' previous theoretical analysis of thrust imbalance with actual Space Shuttle performance. The theoretical prediction method, which involves a Monte Carlo technique, is reviewed briefly as are salient features of the flight instrumentation system and the statistical analysis. A scheme for smoothing flight data is discussed. The effects of changes in design parameters are discussed with special emphasis on the filament wound motor case being developed to replace the steel case. Good agreement between the predictions and the flight data is demonstrated.

Foster, W. A., Jr.↗
NASA NTRS1992

Pluto flyby mission design concepts for very small and moderate spacecraft

This paper discusses the trade-offs involved in the design of a Pluto flyby mission using a low-mass spacecraft, the objective of which is the first-ever reconnaissance of the Pluto/Charon system. The analyses include launch opportunity/trajectory identification/launch vehicle trades, flight time vs net spacecraft mass trades, and flyby targeting considerations. Two mission concepts currently under development are discussed. One concept involves an 83 kg dry spacecraft which uses a direct trajectory and a Titan IV/Centaur (with two solid rocket motor upper stages) to reach Pluto in 7 years. The other design is a 316 kg dry spacecraft which uses a 3+Delta VEJGA trajectory and a Delta II (7925) to arrive at Pluto in 13.6 years.

Weinstein, S. S.↗
NASA NTRS2006

Torque Production in a Halbach Machine

The NASA John H. Glenn Research Center initiated the investigation of torque production in a Halbach machine for the Levitated Ducted Fan (LDF) Project to obtain empirical data in determining the feasibility of using a Halbach motor for the project. LDF is a breakthrough technology for "Electric Flight" with the development of a clean, quiet, electric propulsor system. Benefits include zero emissions, decreased dependence on fossil fuels, increased efficiency, increased reliability, reduced maintenance, and decreased operating noise levels. A commercial permanent magnet brushless motor rotor was tested with a custom stator. An innovative rotor utilizing a Halbach array was designed and developed to fit directly into the same stator. The magnets are oriented at 90deg to the adjacent magnet, which cancels the magnetic field on the inside of the rotor and strengthens the field on the outside of the rotor. A direct comparison of the commercial rotor and the Halbach rotor was made. In addition, various test models were designed and developed to validate the basic principles described, and the theoretical work that was performed. The report concludes that a Halbach array based motor can provide significant improvements in electric motor performance and reliability.

Eichenberg, Dennis J.↗
NASA NTRS2023

Development Unit for In-Space Pneumatic Helium Transfer Compressor

High-pressure gaseous helium (GHe) plays a critical role in spacecraft propulsion due to its near exclusive use for pressurization of propellant tanks. Several different designs for helium compressor technologies have been developed for use on Earth; however, significant design changes are required to meet the power, thermal/heat dissipation, vacuum, vibration/shock, size, mass, and efficiency requirements needed for space and launch environments. Currently, no capability exists for mass efficient on-orbit GHe (or xenon) transfer, nor has it ever been attempted. This effort proposed several challenging requirements for the vendor to develop a one-of-a-kind pneumatic compressor prototype. In order to develop a compressor prototype at a TRL 4, a partnership with Air Squared, Inc. was established. This CIF project concluded with the receipt of a prototype along with a proposed design for a flight unit; however, it will not be built due to funding limitations. The vendor had moderate success with initial testing of the prototype at lower pressures (with shimming configured for low pressure). There were delays with testing since the unit was built for higher pressures and the low pressure shimming was challenging to implement. It was found that operation of the compressor at lower pressures caused increased friction on the motor shaft which resulted in the unit drawing more power (current). This was initially thought to be a motor or controller defect. Subsequent high pressure testing at KSC showed that the friction was reduced for the optimal design point (with a high pressure shimming configuration) and the motor (and controller) performed nominally. Following the vendor testing, the unit was tuned/shimmed for a nominal inlet pressure and shipped to KSC for high pressure testing using the custom-designed setup in the Vehicle Assembly Building. The unit performed well, showing the capability to achieve over higher pressure of compression. The pressure differential could likely increase, however, the maximum output of the power supply used for testing was reached, limiting the compressor motor’s capability. Following the GN2 testing, the test setup was converted to GHe with at high pressure. It was shown that although the unit was unable to achieve similar high pressure differentials due to reverse leakage of the GHe through the scroll tip seals, it did achieve the desired GHe compression. This may still be useful for some applications, however, for the purpose of on-orbit GHe transfer, the single stage design would need to be changed to include multiple stages to achieve the compression goals initially proposed by the project.

Brian Nufer↗
NASA NTRS2010

Regenerative Blower for EVA Suit Ventilation Fan

Portable life support systems in future space suits will include a ventilation subsystem driven by a dedicated fan. This ventilation fan must meet challenging requirements for pressure rise, flow rate, efficiency, size, safety, and reliability. This paper describes research and development that showed the feasibility of a regenerative blower that is uniquely suited to meet these requirements. We proved feasibility through component tests, blower tests, and design analysis. Based on the requirements for the Constellation Space Suit Element (CSSE) Portable Life Support System (PLSS) ventilation fan, we designed the critical elements of the blower. We measured the effects of key design parameters on blower performance using separate effects tests, and used the results of these tests to design a regenerative blower that will meet the ventilation fan requirements. We assembled a proof-of-concept blower and measured its performance at sub-atmospheric pressures that simulate a PLSS ventilation loop environment. Head/flow performance and maximum efficiency point data were used to specify the design and operating conditions for the ventilation fan. We identified materials for the blower that will enhance safety for operation in a lunar environment, and produced a solid model that illustrates the final design. The proof-of-concept blower produced the flow rate and pressure rise needed for the CSSE ventilation subsystem while running at 5400 rpm, consuming only 9 W of electric power using a non-optimized, commercial motor and controller and inefficient bearings. Scaling the test results to a complete design shows that a lightweight, compact, reliable, and low power regenerative blower can meet the performance requirements for future space suit life support systems.

Izenson, Michael G.↗
NASA NTRS2010

Development and Acceptance Testing of the Dual Wheel Mechanism for the Tunable Filter Imager Cryogenic Instrument on the JWST

The James Webb Space Telescope (JWST) will carry four scientific instruments, one of which is the Tunable Filter Imager (TFI), which is an instrument within the Fine Guidance Sensor. The Dual Wheel (DW) mechanism is being designed, built and tested by COM DEV Ltd. under contract from the Canadian Space Agency. The DW mechanism includes a pupil wheel (PW) holding seven coronagraphic masks and two calibration elements and a filter wheel (FW) holding nine blocking filters. The DW mechanism must operate at both room temperature and at 35K. Successful operation at 35K comprises positioning each optical element with the required repeatability, for several thousand occasions over the five year mission. The paper discusses the results of testing geared motors and bearings at the cryogenic temperature. In particular bearing retainer design and PGM-HT material, the effects of temperature gradients across bearings and the problems associated with cooling mechanisms down to cryogenic temperatures. The results of additional bearing tests are described that were employed to investigate an abnormally high initial torque experienced at cryogenic temperatures. The findings of these tests, was that the bearing retainer and the ball/race system could be adversely affected by the large temperature change from room temperature to cryogenic temperature and also the temperature gradient across the bearing. The DW mechanism is now performing successfully at both room temperature and at cryogenic temperature. The life testing of the mechanism is expected to be completed in the first quarter of 2010.

Leckie, Martin↗
NASA NTRS1990

Preliminary design of an advanced Stirling system for terrestrial solar energy conversion

A preliminary design was generated for an advanced Stirling conversion system (ASCS) that will be capable of delivering about 25 kW of electric power to an electric utility grid. Stirling engines are being evaluated for terrestrial solar applications. A two-year task to complete detailed design, fabrication, assembly and testing of an ASCS prototype began in April, 1990. The ASCS is designed to deliver maximum power per year over a range of solar inputs with a design life of 30 years (60,000 h). The ACSC has a long-term cost goal of about $450 per kilowatt, exclusive of the 11-m parabolic dish concentrator. The proposed system includes a Stirling engine with high-pressure hydraulic output, coupled with a bent axis variable displacement hydraulic motor and a rotary induction generator. The major thrusts of the preliminary design are described, including material selection for the hot-end components, heat transport system (reflux pool boiler) design, system thermal response, improved manufacturability, FMECA/FTA analysis, updated manufacturing cost estimate, and predicted system performance.

White, M. A.↗
NASA NTRS2020

A Modeling Approach for Handling Qualities and Controls Safety Analysis of Electric Air Taxi Vehicles

The combination of modern advances in electric propulsion, fly-by-wire controls, autonomy, and increasing demand for short range air taxi operations, is currently producing an outburst of vehicle designs more diverse than ever before. Advanced software tools are needed to support the rapid and safe introduction of any design into the airspace, including the safety of the deployed flight control system and vehicle handling qualities. This paper presents a methodology for building air taxi vehicle models with distributed electric propulsion for use in analyzing flight control system safety at the conceptual design level.The approach builds on existing software tools capable of outputting aeromechanics-based linear perturbation models for Vertical Take-off and Landing vehicles with multiple rotors. Rotor torque inputs are then converted into equivalent voltage control inputs, and the linear state and input dynamics matrices are modified to include electric motor dynamics with common parameters for direct-current electric motors. The linear perturbation dynamics are then stitched across multiple operating points into a quasi-Linear Parameter Varying model that covers the full flight envelope. A Model Predictive Controller is developed for use with the full envelope model, and a tradeoff analysis between handling quality and motor requirements is demonstrated using a six passenger NASA air taxi reference design.

Urban Air Mobility↗
NASA NTRS2014

Customizing Countermeasure Prescriptions using Predictive Measures of Sensorimotor Adaptability

Astronauts experience sensorimotor disturbances during the initial exposure to microgravity and during the readapation phase following a return to a gravitational environment. These alterations may lead to disruption in the ability to perform mission critical functional tasks during and after these gravitational transitions. Astronauts show significant inter-subject variation in adaptive capability following gravitational transitions. The ability to predict the manner and degree to which each individual astronaut will be affected would improve the effectiveness of a countermeasure comprised of a training program designed to enhance sensorimotor adaptability. Due to this inherent individual variability we need to develop predictive measures of sensorimotor adaptability that will allow us to predict, before actual space flight, which crewmember will experience challenges in adaptive capacity. Thus, obtaining this information will allow us to design and implement better sensorimotor adaptability training countermeasures that will be customized for each crewmember's unique adaptive capabilities. Therefore the goals of this project are to: 1) develop a set of predictive measures capable of identifying individual differences in sensorimotor adaptability, and 2) use this information to design sensorimotor adaptability training countermeasures that are customized for each crewmember's individual sensorimotor adaptive characteristics. To achieve these goals we are currently pursuing the following specific aims: Aim 1: Determine whether behavioral metrics of individual sensory bias predict sensorimotor adaptability. For this aim, subjects perform tests that delineate individual sensory biases in tests of visual, vestibular, and proprioceptive function. Aim 2: Determine if individual capability for strategic and plastic-adaptive responses predicts sensorimotor adaptability. For this aim, each subject's strategic and plastic-adaptive motor learning abilities are assessed using a test of locomotor function designed specifically to delineate both mechanisms. Aim 3: Develop predictors of sensorimotor adaptability using brain structural and functional metrics. We will measure individual differences in regional brain volumes (structural MRI), white matter integrity (diffusion tensor imaging, or DTI), functional network integrity (resting state functional connectivity MRI), and sensorimotor adaptation task-related functional brain activation (functional MRI). We decided to complete the data collection for Specific Aims 1, 2 and 3 simultaneously on the same subjects to increase data capture. By having the same subjects perform all three specific aims we can enhance our ability to detect how a wider range of factors can predict adaptability in a specific individual. This provides a much richer database and potentially a better understanding of the predictive power of the selected factors. In this presentation I will discuss preliminary data obtained to date.

Bloomberg, J. J.↗
NASA NTRS1996

Dynamics and Control of Orbiting Space Structures NASA Advanced Design Program (ADP)

The report summarizes the advanced design program in the mechanical engineering department at Vanderbilt University for the academic years 1994-1995 and 1995-1996. Approximately 100 students participated in the two years of the subject grant funding. The NASA-oriented design projects that were selected included lightweight hydrogen propellant tank for the reusable launch vehicle, a thermal barrier coating test facility, a piezoelectric motor for space antenna control, and a lightweight satellite for automated materials processing. The NASA supported advanced design program (ADP) has been a success and a number of graduates are working in aerospace and are doing design.

Cruse, T. A.↗