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Orbital Express Advanced Video Guidance Sensor

In May 2007 the first US fully autonomous rendezvous and capture was successfully performed by DARPA's Orbital Express (OE) mission. Since then, the Boeing ASTRO spacecraft and the Ball Aerospace NEXTSat have performed multiple rendezvous and docking maneuvers to demonstrate the technologies needed for satellite servicing. MSFC's Advanced Video Guidance Sensor (AVGS) is a primary near-field proximity operations sensor integrated into ASTRO's Autonomous Rendezvous and Capture Sensor System (ARCSS), which provides relative state knowledge to the ASTRO GN&C system. This paper provides an overview of the AVGS sensor flying on Orbital Express, and a summary of the ground testing and on-orbit performance of the AVGS for OE. The AVGS is a laser-based system that is capable of providing range and bearing at midrange distances and full six degree-of-freedom (6DOF) knowledge at near fields. The sensor fires lasers at two different frequencies to illuminate the Long Range Targets (LRTs) and the Short Range Targets (SRTs) on NEXTSat. Subtraction of one image from the other image removes extraneous light sources and reflections from anything other than the corner cubes on the LRTs and SRTs. This feature has played a significant role for Orbital Express in poor lighting conditions. The very bright spots that remain in the subtracted image are processed by the target recognition algorithms and the inverse-perspective algorithms, to provide 3DOF or 6DOF relative state information. Although Orbital Express has configured the ASTRO ARCSS system to only use AVGS at ranges of 120 m or less, some OE scenarios have provided opportunities for AVGS to acquire and track NEXTSat at greater distances. Orbital Express scenarios to date that have utilized AVGS include a berthing operation performed by the ASTRO robotic arm, sensor checkout maneuvers performed by the ASTRO robotic arm, 10-m unmated operations, 30-m unmated operations, and Scenario 3-1 anomaly recovery. The AVGS performed very well during the pre-unmated operations, effectively tracking beyond its 10-degree Pitch and Yaw limit-specifications, and did not require I-LOAD adjustments before unmated operations. AVGS provided excellent performance in the 10-m unmated operations, effectively tracking and maintaining lock for the duration of this scenario, and showing good agreement between the short and long range targets. During the 30-m unmated operations, the AVGS continuously tracked the SRT to 31.6 m, exceeding expectations, and continuously tracked the LRT from 8.8 m out to 31.6 m, with good agreement between these two target solutions. After this scenario was aborted at a 10-m separation during remate operations, the AVGS tracked the LRT out 54.3 m, until the relative attitude between the vehicles was too large. The vehicles remained apart for eight days, at ranges from 1 km to 6 km. During the approach to remate in this recovery operation, the AVGS began tracking the LRT at 150 m, well beyond the OE planned limits for AVGS ranges, and functioned as the primary sensor for the autonomous rendezvous and docking.

Howard, Ricky↗

Compression Strength of Sulfur Concrete Subjected to Extreme Cold

Sulfur concrete cubes were cycled between liquid nitrogen and room temperature to simulate extreme exposure conditions. Subsequent compression testing showed the strength of cycled samples to be roughly five times less than those non-cycled. Fracture surface examination showed de-bonding of the sulfur from the aggregate material in the cycled samples but not in those non-cycled. The large discrepancy found, between the samples is attributed to the relative thermal properties of the materials constituting the concrete.

Grugel, Richard N.↗

Spatial Modulation Improves Performance in CTIS

Suitably formulated spatial modulation of a scene imaged by a computed-tomography imaging spectrometer (CTIS) has been found to be useful as a means of improving the imaging performance of the CTIS. As used here, "spatial modulation" signifies the imposition of additional, artificial structure on a scene from within the CTIS optics. The basic principles of a CTIS were described in "Improvements in Computed- Tomography Imaging Spectrometry" (NPO-20561) NASA Tech Briefs, Vol. 24, No. 12 (December 2000), page 38 and "All-Reflective Computed-Tomography Imaging Spectrometers" (NPO-20836), NASA Tech Briefs, Vol. 26, No. 11 (November 2002), page 7a. To recapitulate: A CTIS offers capabilities for imaging a scene with spatial, spectral, and temporal resolution. The spectral disperser in a CTIS is a two-dimensional diffraction grating. It is positioned between two relay lenses (or on one of two relay mirrors) in a video imaging system. If the disperser were removed, the system would produce ordinary images of the scene in its field of view. In the presence of the grating, the image on the focal plane of the system contains both spectral and spatial information because the multiple diffraction orders of the grating give rise to multiple, spectrally dispersed images of the scene. By use of algorithms adapted from computed tomography, the image on the focal plane can be processed into an image cube a three-dimensional collection of data on the image intensity as a function of the two spatial dimensions (x and y) in the scene and of wavelength (lambda). Thus, both spectrally and spatially resolved information on the scene at a given instant of time can be obtained, without scanning, from a single snapshot; this is what makes the CTIS such a potentially powerful tool for spatially, spectrally, and temporally resolved imaging. A CTIS performs poorly in imaging some types of scenes in particular, scenes that contain little spatial or spectral variation. The computed spectra of such scenes tend to approximate correct values to within acceptably small errors near the edges of the field of view but to be poor approximations away from the edges. The additional structure imposed on a scene according to the present method enables the CTIS algorithms to reconstruct acceptable approximations of the spectral data throughout the scene.

Bearman, Gregory H.↗

John F. Kennedy Space Center's Technology Development and Application 2006-2007 Report

Topics covered include: Reversible Chemochromic Hydrogen Detectors; Determining Trajectory of Triboelectrically Charged Particles, Using Discrete Element Modeling; Using Indium Tin Oxide To Mitigate Dust on Viewing Ports; High-Performance Polyimide Powder Coatings; Controlled-Release Microcapsules for Smart Coatings for Corrosion Applications; Aerocoat 7 Replacement Coatings; Photocatalytic Coatings for Exploration and Spaceport Design; New Materials for the Repair of Polyimide Electrical Wire Insulation; Commodity-Free Calibration; Novel Ice Mitigation Methods; Crack Offset Measurement With the Projected Laser Target Device; New Materials for Structural Composites and Protective Coatings; Fire Chemistry Testing of Spray-On Foam Insulation (SOFI); Using Aerogel-Based Insulation Material To Prevent Foam Loss on the Liquid-Hydrogen Intertank; Particle Ejection and Levitation Technology (PELT); Electrostatic Characterization of Lunar Dust; Numerical Analysis of Rocket Exhaust Cratering; RESOLVE Projects: Lunar Water Resource Demonstration and Regolith Volatile Characterization; Tribocharging Lunar Soil for Electrostatic Beneficiation; Numerically Modeling the Erosion of Lunar Soil by Rocket Exhaust Plumes; Trajectory Model of Lunar Dust Particles; Using Lunar Module Shadows To Scale the Effects of Rocket Exhaust Plumes; Predicting the Acoustic Environment Induced by the Launch of the Ares I Vehicle; Measuring Ultrasonic Acoustic Velocity in a Thin Sheet of Graphite Epoxy Composite; Hail Size Distribution Mapping; Launch Pad 39 Hail Monitor Array System; Autonomous Flight Safety System - Phase III; The Photogrammetry Cube; Bird Vision System; Automating Range Surveillance Through Radio Interferometry and Field Strength Mapping Techniques; Next-Generation Telemetry Workstation; GPS Metric Tracking Unit; and Space-Based Range.

Source record↗

Mineralogy of the Lunar Crust in Spatial Context: First Results from the Moon Mineralogy Mapper (M3)

India's Chandrayaan-1 successfully launched October 22, 2008 and went into lunar orbit a few weeks later. Commissioning of instruments began in late November and was near complete by the end of the year. Initial data for NASA's Moon Mineralogy Mapper (M3) were acquired across the Orientale Basin and the science results are discussed here. M 3 image-cube data provide mineralogy of the surface in geologic context. A major new result is that the existence and distribution of massive amounts of anorthosite as a continuous stratigraphic crustal layer is now irrefutable.

Pieters, C. M.↗

Modeling of the Ablation of Fibrous Materials in the Knudsen Regime

During atmospheric entry of planetary probes, the thermal protection system (TPS) of the probe is exposed to high temperatures under low pressures. In these conditions, carbonous TPS materials undergo gasification in the Knudsen regime leading to mass loss and wall recession called ablation. This work aims to improve the understanding of materiaVenvironment interactions through a study of the coupling between carbon dioxide transport in the Knudsen regime, heterogeneous oxidation of carbon, and sutface recession. A 3D Monte-Carlo simulation tool is used for this study. The fibrous architecture of the materiils, consisting of high porosity random array of carbon fibers, is numerically reproduced on a 3D Cartesian grid. Mass transport in the Knudsen regime from the boundary layer to the surface, and inside this porous material is simulated by random walk. A reaction probability is used to simulate the heterogeneous oxidation reaction. The surface recession is followed by front tracking using a simplified marching cube approach. The output data of the simulations are ablation velocity and dynamic evolution of the material porosity. A parametric study is carried out to analyze the material behavior as a function of Knudsen number for the porous media (length of the mean free path compared to the mean pore diameter) and the intrinsic reactivity of the carbon fibers. The results enable extrapolation of laboratory experimental data to actual entry conditions.

Lachaud, J.↗

Thermal Design, Test and Analysis of PharmaSat, a Small Class D Spacecraft with a Biological Experiment

Small spacecraft have been increasing in popularity because of their low cost, short turnaround and relative efficiency. In the past, small spacecraft have been primarily used for technology demonstrations, but advances in technology have made the miniaturization of space science possible [1,2]. PharmaSat is a low cost, small three cube size spacecraft, with a biological experiment on board, built at NASA (National Aeronautics and Space Administration) Ames Research Center. The thermal design of small spacecraft presents challenges as their smaller surface areas translate into power and thermal constraints. The spacecraft is thermally designed to run colder in the Low Earth Orbit space environment, and heated to reach the temperatures required by the science payload. The limited power supply obtained from the solar panels on small surfaces creates a constraint in the power used to heat the payload to required temperatures. The pressurized payload is isolated with low thermally conductance paths from the large ambient temperature changes. The thermal design consists of different optical properties of section surfaces, Multi Layer Insulation (MLI), low thermal conductance materials, flexible heaters and thermal spreaders. The payload temperature is controlled with temperature sensors and flexible heaters. Finite Element Analysis (FEA) and testing were used to aid the thermal design of the spacecraft. Various tests were conducted to verify the thermal design. An infrared imager was used on the electronic boards to find large heat sources and eliminate any possible temperature runaways. The spacecraft was tested in a thermal vacuum chamber to optimize the thermal and power analysis and qualify the thermal design of the spacecraft for the mission.

Diaz-Aguado, Millan F.↗

Spatial Cognitive Performance During Adaptation to Conflicting Tilt-Translation Stimuli as a Sensorimotor Spaceflight Analog

The need to resolve new patterns of sensory feedback in altered gravitoinertial environments requires cognitive processes to develop appropriate reference frames for spatial orientation awareness. The purpose of this study was to examine deficits in spatial cognitive performance during adaptation to conflicting tilt-translation stimuli. Fourteen subjects were tilted within a lighted enclosure that simultaneously translated at one of 3 frequencies. Tilt and translation motion was synchronized to maintain the resultant gravitoinertial force aligned with the longitudinal body axis, resulting in a mismatch analogous to spaceflight in which the canals and vision signal tilt while the otoliths do not. Changes in performance on different spatial cognitive tasks were compared 1) without motion, 2) with tilt motion alone (pitch at 0.15, 0.3 and 0.6 Hz or roll at 0.3 Hz), and 3) with conflicting tilt-translation motion. The adaptation paradigm was continued for up to 30 min or until the onset of nausea. The order of the adaptation conditions were counter-balanced across 4 different test sessions. There was a significant effect of stimulus frequency on both motion sickness and spatial cognitive performance. Only 3 of 14 were able to complete the full 30 min protocol at 0.15 Hz, while 7 of 14 completed 0.3 Hz and 13 of 14 completed 0.6 Hz. There were no changes in simple visual-spatial cognitive tests, e.g., mental rotation or match-to-sample. There were significant deficits during 0.15 Hz adaptation in both accuracy and reaction time during a spatial reference task in which subjects are asked to identify a match of a 3D reoriented cube assemblage. Our results are consistent with antidotal reports of cognitive impairment that are common during sensorimotor adaptation with G-transitions. We conclude that these cognitive deficits stem from the ambiguity of spatial reference frames for central processing of inertial motion cues.

Kayanickupuram, A. J.↗

Recirculation of Laser Power in an Atomic Fountain

A new technique for laser-cooling atoms in a cesium atomic fountain frequency standard relies on recirculation of laser light through the atom-collection region of the fountain. The recirculation, accomplished by means of reflections from multiple fixed beam-splitter cubes, is such that each of two laser beams makes three passes. As described below, this recirculation scheme offers several advantages over prior designs, including simplification of the laser system, greater optical power throughput, fewer optical and electrical connections, and simplification of beam power balancing. A typical laser-cooled cesium fountain requires the use of six laser beams arranged as three orthogonal pairs of counter-propagating beams to decelerate the atoms and hold them in a three-dimensional optical trap in vacuum. Typically, these trapping/cooling beams are linearly polarized and are positioned and oriented so that (1) counter-propagating beams in each pair have opposite linear polarizations and (2) three of the six orthogonal beams have the sum of their propagation directions pointing up, while the other three have the sum of their propagation directions pointing down. In a typical prior design, two lasers are used - one to generate the three "up" beams, the other to generate the three "down" beams. For this purpose, the output of each laser is split three ways, then the resulting six beams are delivered to the vacuum system, independently of each other, via optical fibers. The present recirculating design also requires two lasers, but the beams are not split before delivery. Instead, only one "up" beam and one oppositely polarized "down" beam are delivered to the vacuum system, and each of these beams is sent through the collection region three times. The polarization of each beam on each pass through the collection region is set up to yield the same combination of polarization and propagation directions as described above. In comparison with the prior design, the present recirculating design utilizes the available laser light more efficiently, making it possible to trap more atoms at a given laser power or the same number of atoms at a lower laser power. The present design is also simpler in that it requires fewer optical fibers, fiber couplings, and collimators, and fewer photodiodes for monitoring beam powers. Additionally, the present design alleviates the difficulty of maintaining constant ratios among power levels of the beams within each "up" or "down" triplet.

Enzer, Daphna G.↗

Magnet-Based System for Docking of Miniature Spacecraft

A prototype system for docking a miniature spacecraft with a larger spacecraft has been developed by engineers at the Johnson Space Center. Engineers working on Mini AERCam, a free-flying robotic camera, needed to find a way to successfully dock and undock their miniature spacecraft to refuel the propulsion and recharge the batteries. The subsystems developed (see figure) include (1) a docking port, designed for the larger spacecraft, which contains an electromagnet, a ball lock mechanism, and a service probe; and (2) a docking cluster, designed for the smaller spacecraft, which contains either a permanent magnet or an electromagnet. A typical docking operation begins with the docking spacecraft maneuvering into position near the docking port on the parent vehicle. The electromagnet( s) are then turned on, and, if necessary, the docking spacecraft is then maneuvered within the capture envelope of the docking port. The capture envelope for this system is approximated by a 5-in. (12.7-cm) cube centered on the front of the docking-port electromagnet and within an angular misalignment of <30 . Thereafter, the magnetic forces draw the smaller spacecraft toward the larger one and this brings the spacecraft into approximate alignment prior to contact. Mechanical alignment guides provide the final rotational alignment into one of 12 positions. Once the docking vehicle has been captured magnetically in the docking port, the ball-lock mechanism is activated, which locks the two spacecraft together. At this point the electromagnet( s) are turned off, and the service probe extended if recharge and refueling are to be performed. Additionally, during undocking, the polarity of one electromagnet can be reversed to provide a gentle push to separate the two spacecraft. This system is currently being incorporated into the design of Mini AERCam vehicle.

Howard, Nathan↗

Cargo-Positioning System for Next-Generation Spacecraft

A report discusses a proposed system for mounting loaded pallets in the cargo bay of a next-generation space-shuttle-like spacecraft, such that the center of mass of the cargo would lie within a 1-in. (2.54-cm) cube that would also contain the center of mass of the spacecraft. The system would include (1) an algorithm for planning the locations of the pallets, given the geometric and weight properties of the pallets, and the geometric restrictions of the cargo bay; (2) quick-connect/quick-disconnect mounting mechanisms similar to those now used on air hoses; (3) other mounting mechanisms, comprising mostly spring-loaded pins, in a locking subsystem that would prevent shifting of the pallets under load; and (4) mechanisms for performing fine position adjustments to satisfy the center-of-mass requirement. The position- adjusting mechanisms would be motor-driven lead-screw mechanisms in groups of three - one for positioning each pin of the locking subsystem along each of three mutually perpendicular coordinate axes. The system also would include a triple-threaded screw that would provide compensation for thermal expansion or contraction of the spacecraft.

Holladay, Jon↗

Computation of Earth Science Products on Spaceborne Platforms

Spaceborne sensors like NASA's Hyperion hyperspectral imager generate huge data volumes, and several near-term trends indicate that data volumes will only increase. Next-generation hyperspectral missions, such as NASA's Hyperspectral Infrared Imager (HyspIRI), will operate at higher duty cycles and higher data rates, and their users will expect products to be generated from the data in near real time [1]. Barring a sudden advance in satellite downlink capacity, these trends point to a need to process data and generate products onboard the spacecraft. Rather than downlink an entire hyperspectral image cube, onboard processing enables satellites to downlink partial or completed scientific data products, which are often one to two orders of magnitude smaller than the original image. In addition, a satellite with onboard data processing resources and direct broadcast transmission equipment could send data products directly to first responders, research scientists or other users on the ground. Next-generation space-capable data processors will have a combination of reconfigurable gate arrays, digital signal processors and general-purpose CPUs. Correctly programmed and configured, these resources are sufficient to run sophisticated data analysis programs, including hyperspectral image processing algorithms that commonly run on desktop computers [2]. This paper describes how we implemented one such program, the HSEG hierarchical image segmentation algorithm, software commonly used on desktop and parallel processors, on a hardware platform designed to mimic a next-generation space-capable data processor [3]. We also describe our approach to porting the algorithm to and optimizing it for the new platform, and determine the expected performance gains enabled by our design. This extended abstract will describe the HSEG algorithm and hardware platform in greater detail, provide an analysis of the key function within the algorithm that required hardware acceleration, and describe our implementation of that function in hardware.

Fisher, Kevin↗

Development of a Solar Array Drive Assembly for CubeSat

Small satellites and in particular CubeSats, have increasingly become more viable as platforms for payloads typically requiring much larger bus structures. As advances in technology make payloads and instruments for space missions smaller, lighter and more power efficient, a niche market is emerging from the university community to perform rapidly developed, low-cost missions on very small spacecraft - micro, nano, and picosatellites. In just the last few years, imaging, biological and new technology demonstration missions have been either proposed or have flown using variations of the CubeSat structure as a basis. As these missions have become more complex, and the CubeSat standard has increased in both size (number of cubes) and mass, available power has become an issue. Body-mounted solar cells provide a minimal amount of power; deployable arrays improve on that baseline but are still limited. To truly achieve maximum power, deployed tracked arrays are necessary. To this end, Honeybee Robotics Spacecraft Mechanisms Corporation, along with MMA of Nederland Colorado, has developed a solar array drive assembly (SADA) and deployable solar arrays specifically for CubeSat missions. In this paper, we discuss the development of the SADA.

Passaretti, Mike↗

Life Science Research in Outer Space: New Platform Technologies for Low-Cost, Autonomous Small Satellite Missions

We develop integrated instruments and platforms suitable for economical, frequent space access for autonomous life science experiments and processes in outer space. The technologies represented by three of our recent free-flyer small-satellite missions are the basis of a rapidly growing toolbox of miniaturized biologically/biochemically-oriented instrumentation now enabling a new generation of in-situ space experiments. Autonomous small satellites (~ 1 50 kg) are less expensive to develop and build than fullsize spacecraft and not subject to the comparatively high costs and scheduling challenges of human-tended experimentation on the International Space Station, Space Shuttle, and comparable platforms. A growing number of commercial, government, military, and civilian space launches now carry small secondary science payloads at far lower cost than dedicated missions; the number of opportunities is particularly large for so-called cube-sat and multicube satellites in the 1 10 kg range. The recent explosion in nano-, micro-, and miniature technologies, spanning fields from telecommunications to materials to bio/chemical analysis, enables development of remarkably capable autonomous miniaturized instruments to accomplish remote biological experimentation. High-throughput drug discovery, point-of-care medical diagnostics, and genetic analysis are applications driving rapid progress in autonomous bioanalytical technology. Three of our recent missions exemplify the development of miniaturized analytical payload instrumentation: GeneSat-1 (launched: December 2006), PharmaSat (launched: May 2009), and O/OREOS (organism/organics exposure to orbital stresses; scheduled launch: May 2010). We will highlight the overall architecture and integration of fluidic, optical, sensor, thermal, and electronic technologies and subsystems to support and monitor the growth of microorganisms in culture in these small autonomous space satellites, including real-time tracking of their culture density, gene expression, and metabolic activity while in the space environment. Flight data and results will be presented from GeneSat-1, which tracked gene expression levels of GFP-labeled E. coli and from PharmaSat, which monitored the dose dependency of an antifungal agent against S. cerevisiae. The O/OREOS SESLO instrument, which will study the effects of radiation and microgravity upon the viability and growth characteristics of B. subtilis and the halophile Halorubrum chaoviatoris for periods of 0 - 6 months in space, will be described as well. The ongoing expansion of the small satellite toolbox of biological technologies will be summarized.

Ricco, Antonio J.↗

Multiscale Modeling of Ablation and Pyrolysis in PICA-Like materials

During atmospheric entry of planetary probes, the thermal protection system (TIPS) of the probe is exposed to high temperatures under low pressures. In these conditions, carbonous fibrous TIPS materials may undergo oxidation leading to mass loss and wall recession called ablation. This work aims to improve the understanding of material/environment interactions through a study of the coupling between oxygen transport in the Knudsen regime, heterogeneous oxidation of carbon, and surface recession. A 3D Random Walk Monte Carlo simulation tool is used for this study. The fibrous architecture of a model material, consisting of high porosity random array of carbon fibers, is numerically represented on a 3D Cartesian grid. Mass transport in the Knudsen regime from the boundary layer to the surface, and inside this porous material is simulated by random walk. A reaction probability is used to simulate the heterogeneous oxidation reaction. The surface recession of the fibers is followed by front tracking using a simplified marching cube approach. The output data of the simulations are ablation velocity and dynamic evolution of the material porosity. A parametric study is carried out to analyze the material behavior as a function of Knudsen number for the porous media (length of the mean free path compared to the mean pore diameter) and the intrinsic reactivity of the carbon fibers. The model is applied to Stardust mission reentry conditions and explains the unexpected behavior of the TIPS material that underwent mass loss in volume.

Lachaud, Jean↗

Large Field Photogrammetry Techniques in Aircraft and Spacecraft Impact Testing

The Landing and Impact Research Facility (LandIR) at NASA Langley Research Center is a 240 ft. high A-frame structure which is used for full-scale crash testing of aircraft and rotorcraft vehicles. Because the LandIR provides a unique capability to introduce impact velocities in the forward and vertical directions, it is also serving as the facility for landing tests on full-scale and sub-scale Orion spacecraft mass simulators. Recently, a three-dimensional photogrammetry system was acquired to assist with the gathering of vehicle flight data before, throughout and after the impact. This data provides the basis for the post-test analysis and data reduction. Experimental setups for pendulum swing tests on vehicles having both forward and vertical velocities can extend to 50 x 50 x 50 foot cubes, while weather, vehicle geometry, and other constraints make each experimental setup unique to each test. This paper will discuss the specific calibration techniques for large fields of views, camera and lens selection, data processing, as well as best practice techniques learned from using the large field of view photogrammetry on a multitude of crash and landing test scenarios unique to the LandIR.

Littell, Justin D.↗

HyspIRI Intelligent Payload Module(IPM) and Benchmarking Algorithms for Upload

Features: Hardware: a) Xilinx Virtex-5 (GSFC Space Cube 2); b) 2 x 400MHz PPC; c) 100MHz Bus; d) 2 x 512MB SDRAM; e) Dual Gigabit Ethernet. Support Linux kernel 2.6.31 (gcc version 4.2.2). Support software running in stand alone mode for better performance. Can stream raw data up to 800 Mbps. Ready for operations. Software Application Examples: Band-stripping Algiotrhmsl:cloud, sulfur, flood, thermal, SWIL, NDVI, NDWI, SIWI, oil spills, algae blooms, etc. Corrections: geometric, radiometric, atmospheric. Core Flight System/dynamic software bus. CCSDS File Delivery Protocol. Delay Tolerant Network. CASPER /onboard planning. Fault monitoring/recovery software. S/C command and telemetry software. Data compression. Sensor Web for Autonomous Mission Operations.

Mandl, Daniel↗

Handheld White Light Interferometer for Measuring Defect Depth in Windows

Accurate quantification of defects (scratches and impacts) is vital to the certification of flight hardware and other critical components. The amount of damage to a particular component contributes to the performance, reliability, and safety of a system, which ultimately affects the success or failure of a mission or test. The launch-commit criteria on a Space Shuttle Orbiter window are governed by the depth of the defects that are identified by a visual inspection. This measurement of a defect is not easy to obtain given the environment, size of the defect, and location of the window(s). The determination of depth has typically been performed by taking a mold impression and measuring the impression with an optical profiling instrument. Another method of obtaining an estimate of the depth is by using a refocus microscope. To use a refocus microscope, the surface of the glass and bottom of the defect are, in turn, brought into focus by the operator. The amount of movement between the two points corresponds to the depth of the defect. The refocus microscope requires a skilled operator and has been proven to be unreliable when used on Orbiter windows. White light interferometry was chosen as a candidate to replace the refocus microscope. The White Light Interferometer (WLI) was developed to replace the refocus microscope as the instrument used for measuring the depth of defects in Orbiter windows. The WLI consists of a broadband illumination source, interferometer, detector, motion control, displacement sensor, mechanical housing, and support electronics. The illumination source for the WLI is typically a visible light emitting diode (LED) or a near-infrared superluminescent diode (SLD) with power levels of less than a milliwatt. The interferometer is a Michelson configuration consisting of a 1-in. (2.5-cm) cube beam splitter, a 0.5-in. (1.3-cm) optical window as a movable leg (used to closely match the return intensity of the fixed leg from the window), and a mirrored prism to fold the optics into the mechanical housing. The detector may be one of many C-mount CCD (charge-coupled device) cameras. Motion is provided by a commercial nanostepping motor with a serial interface. The displacement sensor is a custom device specifically designed for this application. The mechanical housing and support electronics were designed to integrate the various components into an instrument that could be physically handled by a technician and easily transported.

Youngquist, Robert↗