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NASA NTRS2020

A Reflective Framework for Performance Management (REFORM) of Real-Time Hybrid Simulation

Currently, the lack of (1) a sufficiently integrated, adaptive, and reflective framework to ensure the safety, integrity, and coordinated evolution of a real-time hybrid simulation (RTHS) as it runs, and (2) the ability to articulate and gauge suitable measures of the performance and integrity of an experiment, both as it runs and post-hoc, have prevented researchers from tackling a wide range of complex research problems of vital national interest. To address these limitations of the current state-of-the-art, we propose a framework named Reflective Framework for Performance Management (REFORM) of real-time hybrid simulation. REFORM will support the execution of more complex RTHS experiments than can be conducted today, and will allow them to be configured rapidly, performed safely, and analyzed thoroughly. This study provides a description of the building blocks associated with the first phase of this development (REFORM-I). REFORM-I is verified and demonstrated through application to an expanded version of the benchmark control problem for real-time hybrid simulation.

Amin Maghareh↗

NASA NTRS2016

Looking Back in Time: Building the James Webb Space Telescope (JWST) Optical Telescope Element

When it launches in 2018, the James Webb Space Telescope (JWST) will look back in time at the earliest stars and galaxies forming in the universe. This talk will look back in time at the development of the JWST telescope. This will include a discussion of the design, technology development, mirror development, wave front sensing and control algorithms, lightweight cryogenic deployable structure, pathfinder telescope, and integration and test program evolution and status. The talk will provide the engineering answers on why the mirrors are made of Beryllium, why there are 18 segments, where and how the mirrors were made, how the mirrors get aligned using the main science camera, and how the telescope is being tested. It will also look back in time at the many dedicated people all over the country who helped build it.

JWST OTE↗

NASA NTRS2010

High-Temperature Modal Survey of a Hot-Structure Control Surface

Ground vibration tests or modal surveys are routinely conducted for supporting flutter analysis for subsonic and supersonic vehicles; however, for hypersonic vehicle applications, thermoelastic vibration testing techniques are not well established and are not routinely performed for supporting hypersonic flutter analysis. New high-temperature material systems, fabrication technologies and high-temperature sensors expand the opportunities to develop advanced techniques for performing ground vibration tests at elevated temperatures. High-temperature materials have the unique property of increasing in stiffness when heated. When these materials are incorporated into a hot-structure, which includes metallic components that decrease in stiffness with increasing temperature, the interaction between the two materials systems needs to be understood because that interaction could ultimately affect the hypersonic flutter analysis. Performing a high-temperature modal survey will expand the research database for hypersonics and will help build upon the understanding of the dual material interaction. This paper will discuss the vibration testing of the Carbon-Silicon Carbide Ruddervator Subcomponent Test Article which is a truncated version of the full-scale X-37 hot-structure control surface. In order to define the modal characteristics of the test article during the elevated-temperature modal survey, two series of room-temperature modal test configurations had to be performed. The room-temperature test series included one with the test article suspended from a bungee cord (free-free) and the second with it mounted on the strongback (fixed boundary condition) in NASA Dryden's Flight Loads Lab large nitrogen test chamber.

Spivey, Natalie Dawn↗

NASA NTRS1993

Boundary layer receptivity and control

Receptivity processes initiate natural instabilities in a boundary layer. The instabilities grow and eventually break down to turbulence. Consequently, receptivity questions are a critical element of the analysis of the transition process. Success in modeling the physics of receptivity processes thus has a direct bearing on technological issues of drag reduction. The means by which transitional flows can be controlled is also a major concern: questions of control are tied inevitably to those of receptivity. Adjoint systems provide a highly effective mathematical method for approaching many of the questions associated with both receptivity and control. The long term objective is to develop adjoint methods to handle increasingly complex receptivity questions, and to find systematic procedures for deducing effective control strategies. The most elementary receptivity problem is that in which a parallel boundary layer is forced by time-harmonic sources of various types. The characteristics of the response to such forcing form the building blocks for more complex receptivity mechanisms. The first objective of this year's research effort was to investigate how a parallel Blasius boundary layer responds to general direct forcing. Acoustic disturbances in the freestream can be scattered by flow non-uniformities to produce Tollmien-Schlichting waves. For example, scattering by surface roughness is known to provide an efficient receptivity path. The present effort is directed towards finding a solution by a simple adjoint analysis, because adjoint methods can be extended to more complex problems. In practice, flows are non-parallel and often three-dimensional. Compressibility may also be significant in some cases. Recent developments in the use of Parabolized Stability Equations (PSE) offer a promising possibility. By formulating and solving a set of adjoint parabolized equations, a method for mapping the efficiency with which external forcing excites the three-dimensional motions of a non-parallel boundary layer was developed. The method makes use of the same computationally efficient formulation that makes the PSE currently so appealing. In the area of flow control, adjoint systems offer a powerful insight into the effect of control forces. One of the simplest control strategies for boundary layers involves the application of localized mean wall suction.

Hill, D. C.↗

NASA NTRS2006

Evolution and Control of 2219 Aluminum Microstructural Features through Electron Beam Freeform Fabrication

Electron beam freeform fabrication (EBF3) is a new layer-additive process that has been developed for near-net shape fabrication of complex structures. EBF3 uses an electron beam to create a molten pool on the surface of a substrate. Wire is fed into the molten pool and the part translated with respect to the beam to build up a 3-dimensional structure one layer at a time. Unlike many other freeform fabrication processes, the energy coupling of the electron beam is extremely well suited to processing of aluminum alloys. The layer-additive nature of the EBF3 process results in a tortuous thermal path producing complex microstructures including: small homogeneous equiaxed grains; dendritic growth contained within larger grains; and/or pervasive dendritic formation in the interpass regions of the deposits. Several process control variables contribute to the formation of these different microstructures, including translation speed, wire feed rate, beam current and accelerating voltage. In electron beam processing, higher accelerating voltages embed the energy deeper below the surface of the substrate. Two EBF3 systems have been established at NASA Langley, one with a low-voltage (10-30kV) and the other a high-voltage (30-60 kV) electron beam gun. Aluminum alloy 2219 was processed over a range of different variables to explore the design space and correlate the resultant microstructures with the processing parameters. This report is specifically exploring the impact of accelerating voltage. Of particular interest is correlating energy to the resultant material characteristics to determine the potential of achieving microstructural control through precise management of the heat flux and cooling rates during deposition.

Taminger, Karen M.↗

NASA NTRS2010

Developing Expert Teams with a Strong Safety Culture

Would you like to lead a world renowned team that draws out all the talents and expertise of its members and consistently out performs all others in the industry? Ever wonder why so many organizations fail to truly learn from past mistakes only to repeat the same ones at a later date? Are you a program/project manager or team member in a high-risk organization where the decisions made often carry the highest of consequences? Leadership, communication, team building, critical decision-making and continuous team improvement skills and behaviors are mere talking points without the attitudes, commitment and strategies necessary to make them the very fabric of a team. Developing Expert Teams with a Strong Safety Culture, will provide you with proven knowledge and strategies to take your team soaring to heights you may have not thought possible. A myriad of teams have applied these strategies and techniques within their organization team environments: military and commercial aviation, astronaut flight crews, Shuttle flight controllers, members of the Space Shuttle Program Mission Management Team, air traffic controllers, nuclear power control teams, surgical teams, and the fire service report having spectacular success. Many industry leaders are beginning to realize that although the circumstances and environments of these teams may differ greatly to their own, the core elements, governing principles and dynamics involved in managing and building a stellar safety conscious team remain identical.

Rogers, David G.↗

NASA NTRS1998

Development and Testing of Automatically Generated ACS Flight Software for the MAP Spacecraft

By integrating the attitude determination and control system (ACS) analysis and design, flight software development, and flight software testing processes, it is possible to improve the overall spacecraft development cycle, as well as allow for more thorough software testing. One of the ways to achieve this integration is to use code-generation tools to automatically generate components of the ACS flight software directly from a high-fidelity (HiFi) simulation. In the development of the Microwave Anisotropy Probe (MAP) spacecraft, currently underway at the NASA Goddard Space Flight Center, approximately 1/3 of the ACS flight software was automatically generated. In this paper, we will examine each phase of the ACS subsystem and flight software design life cycle: analysis, design, and testing. In the analysis phase, we scoped how much software we would automatically generate and created the initial interface. The design phase included parallel development of the HiFi simulation and the hand-coded flight software components. Everything came together in the test phase, in which the flight software was tested, using results from the HiFi simulation as one of the bases of comparison for testing. Because parts of the spacecraft HiFi simulation were converted into flight software, more care needed to be put into its development and configuration control to support both the HiFi simulation and flight software. The components of the HiFi simulation from which code was generated needed to be designed based on the fact that they would become flight software. This process involved such considerations as protecting against mathematical exceptions, using acceptable module and parameter naming conventions, and using an input/output interface compatible with the rest of the flight software. Maintaining good configuration control was an issue for the HiFi simulation and the flight software, and a way to track the two systems was devised. Finally, an integrated test approach was devised to support flight software testing at both the unit- and build-test levels using the HiFi simulation to generate data for performance verification. Another benefit of the simulation and code-generation application used on the MAP project is that it supported bringing flight software and test data into the HiFi simulation environment. It was possible to integrate parts of the hand-coded flight software into the HiFi simulation, and also possible to import flight software test data for comparison and performance verification. This capability was used to incorporate the flight software Kalman filter into the HiFi simulation. This enabled us to greatly increase the amount of testing that could be done on the filter, because we could exert a greater degree of control over the software-only simulation than over the flight software test environment. Also, since the simulation could be used to run the Kalman filter faster than real time, our testing efficiency was greatly increased. We will conclude our discussion with a summary of the lessons learned thus far using automatically- generated code for the MAP project, and the spacecraft status as we work towards our scheduled launch in the year 2000.

ODonnell, James R., Jr.↗

NASA NTRS2020

Space Launch System Mobile Launcher Modal Pretest Analysis

NASA is developing an expendable heavy lift launch vehicle capability, the Space Launch System, to support lunar and deep space exploration. To support this capability, an updated ground infrastructure is required including modifying an existing Mobile Launcher system. The Mobile Launcher is a very large heavy beam/truss steel structure designed to support the Space Launch System during its buildup and integration in the Vehicle Assembly Building, transportation from the Vehicle Assembly Building out to the launch pad, and provides the launch platform at the launch pad. The previous Saturn/Apollo and Space Shuttle programs had integrated vehicle ground vibration tests of their integrated launch vehicles performed with simulated free-free boundary conditions to experimentally anchor and validate structural and flight controls analysis models. For the Space Launch System program, the Mobile Launcher will be used as the modal test fixture for the ground vibration test of the first Space Launch System flight vehicle, Artemis 1, programmatically referred to as the integrated vehicle modal test. The integrated vehicle modal test of the Artemis 1 integrated launch vehicle will have its core and second stages unfueled while mounted to the Mobile Launcher while inside the Vehicle Assembly Building, which is currently scheduled for the summer of 2020. The Space Launch System program has implemented a building block approach for dynamic model validation. The modal test of the Mobile Launcher is an important part of this building block approach in supporting the integrated vehicle modal test since the Mobile Launcher will serve as a structurally dynamic test fixture whose modes will couple with the modes of the Artemis 1 integrated vehicle. The Mobile Launcher modal test will further support understanding the structural dynamics of the Mobile Launcher and Space Launch System during rollout to the launch pad, which will play a key role in better understanding and prediction of the rollout forces acting on the launch vehicle. The Mobile Launcher modal test is currently scheduled for the summer of 2019. Due to a very tight modal testing schedule, this independent Mobile Launcher modal pretest analysis has been performed to ensure there is a high likelihood of successfully completing the modal test (i.e. identify the primary target modes) using the planned instrumentation, shakers, and excitation types. This paper will discuss this Mobile Launcher modal pretest analysis for its three test configurations and the unique challenges faced due to the Mobile Launcherâ€™s size and weight, which are typically not faced when modal testing aerospace structures.

Akers, James C.↗

NASA NTRS1990

A general-purpose development environment for intelligent computer-aided training systems

Space station training will be a major task, requiring the creation of large numbers of simulation-based training systems for crew, flight controllers, and ground-based support personnel. Given the long duration of space station missions and the large number of activities supported by the space station, the extension of space shuttle training methods to space station training may prove to be impractical. The application of artificial intelligence technology to simulation training can provide the ability to deliver individualized training to large numbers of personnel in a distributed workstation environment. The principal objective of this project is the creation of a software development environment which can be used to build intelligent training systems for procedural tasks associated with the operation of the space station. Current NASA Johnson Space Center projects and joint projects with other NASA operational centers will result in specific training systems for existing space shuttle crew, ground support personnel, and flight controller tasks. Concurrently with the creation of these systems, a general-purpose development environment for intelligent computer-aided training systems will be built. Such an environment would permit the rapid production, delivery, and evolution of training systems for space station crew, flight controllers, and other support personnel. The widespread use of such systems will serve to preserve task and training expertise, support the training of many personnel in a distributed manner, and ensure the uniformity and verifiability of training experiences. As a result, significant reductions in training costs can be realized while safety and the probability of mission success can be enhanced.

Savely, Robert T.↗

NASA NTRS1986

The implementation and use of Ada on distributed systems with high reliability requirements

The general inadequacy of Ada for programming systems that must survive processor loss was shown. A solution to the problem was proposed in which there are no syntatic changes to Ada. The approach was evaluated using a full-scale, realistic application. The application used was the Advanced Transport Operating System (ATOPS), an experimental computer control system developed for a modified Boeing 737 aircraft. The ATOPS system is a full authority, real-time avionics system providing a large variety of advanced features. Methods of building fault tolerance into concurrent systems were explored. A set of criteria by which the proposed method will be judged was examined. Extensive interaction with personnel from Computer Sciences Corporation and NASA Langley occurred to determine the requirements of the ATOPS software. Backward error recovery in concurrent systems was assessed.

Knight, J. C.↗

NASA NTRS1990

A study on diagnosability of space station ECLSS

The use is demonstrated of the Multigraph Architecture (MGA) for studies on the Environment Control and Life Support System (ECLSS). The objective was the following: (1) to create an updated set of models of the Potable Water Subsystem (PWS) by using the graphical model building tools of the Multigraph Programming Environment (MPE); (2) to derive a real time alarm simulator from the models; and (3) to demonstrate the effects of sensor allocation on the diagnosability of the PWS. This work may serve as a preliminary study for the detailed analysis of the sensor allocation and diagnosability problems in the ECLSS.

Padalkar, S.↗

NASA NTRS1995

Nanosatellite Power System Considerations

The capability to build complex electronic functions into compact packages is opening the path to miniature satellites on the order of 1 kg mass, 10 cm across, packed with the computing processors, motion controllers, measurement sensors, and communications hardware necessary for operation. Power generation will be from short strings of silicon or gallium arsenide-based solar photovoltaic cells with the array power maximized by a peak power tracker (PPT). Energy storage will utilize a low voltage battery with nickel cadmium or lithium ion cells as the most likely selections for rechargeables and lithium (MnO2-Li) primary batteries for one shot short missions.

Robyn, M.↗

NASA NTRS1998

1998 JANNAF Propulsion Meeting

This volume, the first of four volumes, is a collection of 40 unclassified/unlimited-distribution papers which were presented at the 1998 Joint Army-Navy-NASA-Air Force (JANNAF) Propulsion Meeting (JPM), held 15-17 July 1998 at the Cleveland Marriott Downtown at Key Center and the Celebreeze Federal Building in Cleveland, Ohio. The 1998 JPM was co-located with the 1998 American Institute of Aeronautics and Astronautics Joint Propulsion Conference. Specific subjects discussed include reusable liquid boosters, controllable solid propulsion, advanced propellants for the 2.75' rocket system, air-turbo-rocket propulsion, issues in gun propulsion, electric propulsion, liquid engine turbomachinery, and new liquid propulsion technology.

Eggleston, Debra S.↗

NASA NTRS2003

Nucleation Behavior of Oxygen-Acetylene Torch-Produced Diamond Films

A mechanism is presented for the nucleation of diamond in the combustion flame environment. A series of six experiments and two associated simulations provide results from which the mechanism was derived. A substantial portion of the prior literature was reviewed and the data and conclusions from the previous experimenters were found to support the proposed mechanism. The nucleation mechanism builds on the work of previous researchers but presents an approach to nucleation in a detail and direction not fully presented heretofore. This work identifies the gas phase as the controlling environment for the initial formation steps leading to nucleation. The developed mechanism explains some of the difficulty which has been found in producing single crystal epitaxial films. An experiment which modified the initial gas phase precursor using methane and carbon monoxide is presented. Addition of methane into the precursor gases was found to be responsible for pillaring of the films. Atomic force microscopy surface roughness data provides a reasonable look at suppression of nucleation by carbon monoxide. Surface finish data was taken on crystals which were open to the nucleation environment and generally parallel to the substrate surface. The test surfaces were measured as an independent measure of the instantaneous nucleation environent. A gas flow and substrate experiment changed the conditions on the surface of the sample by increasing the gas flow rate while remaining on a consistent point of the atomic constituent diagram, and by changing the carbide potential of the substrate. Two tip modification experiments looked at the behavior of gas phase nucleation by modifying the shape and behavior of the flame plasma in which the diamond nucleation is suspected to occur. Diamond nucleation and growth was additionally examined using a high-velocity oxygen fuel gun and C3H6 as the fuel gas phase precursor with addition of carbon monoxide gas 01 addition of liquid toluene.

Roberts, F. E.↗

NASA NTRS2004

Automated Composites Processing Technology: Film Module

NASA's Marshall Space Flight Center (MSFC) has developed a technology that combines a film/adhesive laydown module with fiber placement technology to enable the processing of composite prepreg tow/tape and films, foils or adhesives on the same placement machine. The development of this technology grew out of NASA's need for lightweight, permeation-resistant cryogenic propellant tanks. Autoclave processing of high performance composites results in thermally-induced stresses due to differences in the coefficients of thermal expansion of the fiber and matrix resin components. These stresses, together with the reduction in temperature due to cryogen storage, tend to initiate microcracking within the composite tank wall. One way in which to mitigate this problem is to introduce a thin, crack-resistant polymer film or foil into the tank wall. Investigation into methods to automate the processing of thin film or foil materials into composites led to the development of this technology. The concept employs an automated film supply and feed module that may be designed to fit existing fiber placement machines, or may be designed as integral equipment to new machines. This patent-pending technology can be designed such that both film and foil materials may be processed simultaneously, leading to a decrease in part build cycle time. The module may be designed having a compaction device independent of the host machine, or may utilize the host machine's compactor. The film module functions are controlled by a dedicated system independent of the fiber placement machine controls. The film, foil, or adhesive is processed via pre-existing placement machine run programs, further reducing operational expense.

Hulcher, A. Bruce↗

NASA NTRS2000

ASTROCULTURE (TM) root metabolism and cytochemical analysis

Physiology of the root system is dependent upon oxygen availability and tissue respiration. During hypoxia nutrient and water acquisition may be inhibited, thus affecting the overall biochemical and physiological status of the plant. For the Astroculture (TM) plant growth hardware, the availability of oxygen in the root zone was measured by examining the changes in alcohol dehydrogenase (ADH) activity within the root tissue. ADH activity is a sensitive biochemical indicator of hypoxic conditions in plants and was measured in both spaceflight and control roots. In addition to the biochemical enzyme assays, localization of ADH in the root tissue was examined cytochemically. The results of these analyses showed that ADH activity increased significantly as a result of spaceflight exposure. Enzyme activity increased 248% to 304% in dwarf wheat when compared with the ground controls and Brassica showed increases between 334% and 579% when compared with day zero controls. Cytochemical staining revealed no differences in ADH tissue localization in any of the dwarf wheat treatments. These results show the importance of considering root system oxygenation in designing and building nutrient delivery hardware for spaceflight plant cultivation and confirm previous reports of an ADH response associated with spaceflight exposure.

Flight Experiment↗

NASA NTRS1980

Mount assembly for porous transition panel at annular combustor outlet

A gas turbine engine combustor assembly of annular configuration has outer and inner walls made up of a plurality of axially extending multi-layered porous metal panels joined together at butt joints therebetween and each outer and inner wall including a transition panel of porous metal defining a combustor assembly outlet supported by a combustor mount assembly including a stiffener ring having a side undercut thereon fit over a transition panel end face; and wherein an annular weld joins the ring to the end face to transmit exhaust heat from the end face to the stiffener ring for dissipation from the combustor; a combustor pilot member is located in axially spaced, surrounding relationship to the end face and connector means support the stiffener ring in free floating relationship with the pilot member to compensate for both radial and axial thermal expansion of the transition panel; and said connector means includes a radial gap for maintaining a controlled flow of coolant from outside of the transition panel into cooling relationship with the stiffener ring and said weld to further cool the end face against excessive heat build-up therein during flow of hot gas exhaust through said outlet.

Sweeney, Ralph B.↗

NASA NTRS2008

Orchestrator Telemetry Processing Pipeline

Orchestrator is a software application infrastructure for telemetry monitoring, logging, processing, and distribution. The architecture has been applied to support operations of a variety of planetary rovers. Built in Java with the Eclipse Rich Client Platform, Orchestrator can run on most commonly used operating systems. The pipeline supports configurable parallel processing that can significantly reduce the time needed to process a large volume of data products. Processors in the pipeline implement a simple Java interface and declare their required input from upstream processors. Orchestrator is programmatically constructed by specifying a list of Java processor classes that are initiated at runtime to form the pipeline. Input dependencies are checked at runtime. Fault tolerance can be configured to attempt continuation of processing in the event of an error or failed input dependency if possible, or to abort further processing when an error is detected. This innovation also provides support for Java Message Service broadcasts of telemetry objects to clients and provides a file system and relational database logging of telemetry. Orchestrator supports remote monitoring and control of the pipeline using browser-based JMX controls and provides several integration paths for pre-compiled legacy data processors. At the time of this reporting, the Orchestrator architecture has been used by four NASA customers to build telemetry pipelines to support field operations. Example applications include high-volume stereo image capture and processing, simultaneous data monitoring and logging from multiple vehicles. Example telemetry processors used in field test operations support include vehicle position, attitude, articulation, GPS location, power, and stereo images.

Powell, Mark↗