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89 records · Page 5

Two fault tolerant toggle-hook release

A coupling device is disclosed which is mechanically two fault tolerant for release. The device comprises a fastener plate and fastener body, each of which is attachable to a different one of a pair of structures to be joined. The fastener plate and body are coupled by an elongate toggle mounted at one end in a socket on the fastener plate for universal pivotal movement thereon. The other end of the toggle is received in an opening in the fastener body and adapted for limited pivotal movement therein. The toggle is adapted to be restrained by three latch hooks arranged in symmetrical equiangular spacing about the axis of the toggle, each hook being mounted on the fastener body for pivotal movement between an unlatching non-contact position with respect to the toggle and a latching position in engagement with a latching surface of the toggle. The device includes releasable lock means for locking each latch hook in its latching position whereby the toggle couples the fastener plate to the fastener body and means for releasing the lock means to unlock each said latch hook from the latch position whereby the unlocking of at least one of the latch hooks from its latching position results in the decoupling of the fastener plate from the fastener body.

Graves, Thomas Joseph↗

Runtime Verification in Context : Can Optimizing Error Detection Improve Fault Diagnosis

Runtime verification has primarily been developed and evaluated as a means of enriching the software testing process. While many researchers have pointed to its potential applicability in online approaches to software fault tolerance, there has been a dearth of work exploring the details of how that might be accomplished. In this paper, we describe how a component-oriented approach to software health management exposes the connections between program execution, error detection, fault diagnosis, and recovery. We identify both research challenges and opportunities in exploiting those connections. Specifically, we describe how recent approaches to reducing the overhead of runtime monitoring aimed at error detection might be adapted to reduce the overhead and improve the effectiveness of fault diagnosis.

Dwyer, Matthew B.↗

Rule-based mechanisms of learning for intelligent adaptive flight control

How certain aspects of human learning can be used to characterize learning in intelligent adaptive control systems is investigated. Reflexive and declarative memory and learning are described. It is shown that model-based systems-theoretic adaptive control methods exhibit attributes of reflexive learning, whereas the problem-solving capabilities of knowledge-based systems of artificial intelligence are naturally suited for implementing declarative learning. Issues related to learning in knowledge-based control systems are addressed, with particular attention given to rule-based systems. A mechanism for real-time rule-based knowledge acquisition is suggested, and utilization of this mechanism within the context of failure diagnosis for fault-tolerant flight control is demonstrated.

Handelman, David A.↗

USE OF THE SDO POINTING CONTROLLERS FOR INSTRUMENT CALIBRATION MANEUVERS

During the science phase of the Solar Dynamics Observatory mission, the three science instruments require periodic instrument calibration maneuvers with a frequency of up to once per month. The command sequences for these maneuvers vary in length from a handful of steps to over 200 steps, and individual steps vary in size from 5 arcsec per step to 22.5 degrees per step. Early in the calibration maneuver development, it was determined that the original attitude sensor complement could not meet the knowledge requirements for the instrument calibration maneuvers in the event of a sensor failure. Because the mission must be single fault tolerant, an attitude determination trade study was undertaken to determine the impact of adding an additional attitude sensor versus developing alternative, potentially complex, methods of performing the maneuvers in the event of a sensor failure. To limit the impact to the science data capture budget, these instrument calibration maneuvers must be performed as quickly as possible while maintaining the tight pointing and knowledge required to obtain valid data during the calibration. To this end, the decision was made to adapt a linear pointing controller by adjusting gains and adding an attitude limiter so that it would be able to slew quickly and still achieve steady pointing once on target. During the analysis of this controller, questions arose about the stability of the controller during slewing maneuvers due to the combination of the integral gain, attitude limit, and actuator saturation. Analysis was performed and a method for disabling the integral action while slewing was incorporated to ensure stability. A high fidelity simulation is used to simulate the various instrument calibration maneuvers.

Vess, Melissa F.↗

NASA Tech Briefs, September 2012

Topics covered include: Beat-to-Beat Blood Pressure Monitor; Measurement Techniques for Clock Jitter; Lightweight, Miniature Inertial Measurement System; Optical Density Analysis of X-Rays Utilizing Calibration Tooling to Estimate Thickness of Parts; Fuel Cell/Electrochemical Cell Voltage Monitor; Anomaly Detection Techniques with Real Test Data from a Spinning Turbine Engine-Like Rotor; Measuring Air Leaks into the Vacuum Space of Large Liquid Hydrogen Tanks; Antenna Calibration and Measurement Equipment; Glass Solder Approach for Robust, Low-Loss, Fiber-to-Waveguide Coupling; Lightweight Metal Matrix Composite Segmented for Manufacturing High-Precision Mirrors; Plasma Treatment to Remove Carbon from Indium UV Filters; Telerobotics Workstation (TRWS) for Deep Space Habitats; Single-Pole Double-Throw MMIC Switches for a Microwave Radiometer; On Shaft Data Acquisition System (OSDAS); ASIC Readout Circuit Architecture for Large Geiger Photodiode Arrays; Flexible Architecture for FPGAs in Embedded Systems; Polyurea-Based Aerogel Monoliths and Composites; Resin-Impregnated Carbon Ablator: A New Ablative Material for Hyperbolic Entry Speeds; Self-Cleaning Particulate Prefilter Media; Modular, Rapid Propellant Loading System/Cryogenic Testbed; Compact, Low-Force, Low-Noise Linear Actuator; Loop Heat Pipe with Thermal Control Valve as a Variable Thermal Link; Process for Measuring Over-Center Distances; Hands-Free Transcranial Color Doppler Probe; Improving Balance Function Using Low Levels of Electrical Stimulation of the Balance Organs; Developing Physiologic Models for Emergency Medical Procedures Under Microgravity; PMA-Linked Fluorescence for Rapid Detection of Viable Bacterial Endospores; Portable Intravenous Fluid Production Device for Ground Use; Adaptation of a Filter Assembly to Assess Microbial Bioburden of Pressurant Within a Propulsion System; Multiplexed Force and Deflection Sensing Shell Membranes for Robotic Manipulators; Whispering Gallery Mode Optomechanical Resonator; Vision-Aided Autonomous Landing and Ingress of Micro Aerial Vehicles; Self-Sealing Wet Chemistry Cell for Field Analysis; General MACOS Interface for Modeling and Analysis for Controlled Optical Systems; Mars Technology Rover with Arm-Mounted Percussive Coring Tool, Microimager, and Sample-Handling Encapsulation Containerization Subsystem; Fault-Tolerant, Real-Time, Multi-Core Computer System; Water Detection Based on Object Reflections; SATPLOT for Analysis of SECCHI Heliospheric Imager Data; Plug-in Plan Tool v3.0.3.1; Frequency Correction for MIRO Chirp Transformation Spectroscopy Spectrum; Nonlinear Estimation Approach to Real-Time Georegistration from Aerial Images; Optimal Force Control of Vibro-Impact Systems for Autonomous Drilling Applications; Low-Cost Telemetry System for Small/Micro Satellites; Operator Interface and Control Software for the Reconfigurable Surface System Tri-ATHLETE; and Algorithms for Determining Physical Responses of Structures Under Load.

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Orbiting Rainbows: Optical Manipulation of Aerosols and the Beginnings of Future Space Construction

Our objective is to investigate the conditions to manipulate and maintain the shape of an orbiting cloud of dust-like matter so that it can function as an ultra-lightweight surface with useful and adaptable electromagnetic characteristics, for instance, in the optical, RF, or microwave bands. Inspired by the light scattering and focusing properties of distributed optical assemblies in Nature, such as rainbows and aerosols, and by recent laboratory successes in optical trapping and manipulation, we propose a unique combination of space optics and autonomous robotic system technology, to enable a new vision of space system architecture with applications to ultra-lightweight space optics and, ultimately, in-situ space system fabrication. Typically, the cost of an optical system is driven by the size and mass of the primary aperture. The ideal system is a cloud of spatially disordered dust-like objects that can be optically manipulated: it is highly reconfigurable, fault-tolerant, and allows very large aperture sizes at low cost. See Figure 1 for a scenario of application of this concept. The solution that we propose is to construct an optical system in space in which the nonlinear optical properties of a cloud of micron-sized particles are shaped into a specific surface by light pressure, allowing it to form a very large and lightweight aperture of an optical system, hence reducing overall mass and cost. Other potential advantages offered by the cloud properties as optical system involve possible combination of properties (combined transmit/receive), variable focal length, combined refractive and reflective lens designs, and hyper-spectral imaging. A cloud of highly reflective particles of micron-size acting coherently in a specific electromagnetic band, just like an aerosol in suspension in the atmosphere, would reflect the Sun's light much like a rainbow. The only difference with an atmospheric or industrial aerosol is the absence of the supporting fluid medium. This new concept is based on recent understandings in the physics of optical manipulation of small particles in the laboratory and the engineering of distributed ensembles of spacecraft clouds to shape an orbiting cloud of micron-sized objects. In the same way that optical tweezers have revolutionized micro- and nano-manipulation of objects, our breakthrough concept will enable new large scale NASA mission applications and develop new technology in the areas of Astrophysical Imaging Systems and Remote Sensing because the cloud can operate as an adaptive optical imaging sensor. While achieving the feasibility of constructing one single aperture out of the cloud is the main topic of this work, it is clear that multiple orbiting aerosol lenses could also combine their power to synthesize a much larger aperture in space to enable challenging goals such as exoplanet detection. Furthermore, this effort could establish feasibility of key issues related to material properties, remote manipulation, and autonomy characteristics of cloud in orbit. There are several types of endeavors (science missions) that could be enabled by this type of approach, i.e. it can enable new astrophysical imaging systems, exoplanet search, large apertures allow for unprecedented high resolution to discern continents and important features of other planets, hyperspectral imaging, adaptive systems, spectroscopy imaging through limb, and stable optical systems from Lagrange-points. Future micro-miniaturization might hold promise of a further extension of our dust aperture concept to other more exciting smart dust concepts with other associated capabilities.

Space Construction↗

NASA Tech Briefs, November 1995

The contents include: 1) Mission Accomplished; 2) Resource Report: Marshall Space Flight Center; 3) NASA 1995 Software of the Year Award; 4) Microbolometers Based on Epitaxial YBa2Cu3O(sub 7-x) Thin Films; 5) Garnet Random-Access Memory; 6) Fabrication of SNS Weak Links on SOS Substrates; 7) High-Voltage MOSFET Switching Circuit; 8) Asymmetric Switching for a PWM H-Bridge Power Circuit; 9) Better Ohmic Contacts for InP Semiconductor Devices; 10) Low-Bandgap Thermovoltaic Materials and Devices; 11) Digital Frequency-Differencing Circuit; 12) Imaging Magnetometer; 13) Computer-Assisted Monitoring of a Complex System; 14) Buffered Telemetry Demodulator; 15) Compact Multifunction Inspection Head; 16) Optical Detection of Fractures in Ceramic Diaphragms; 17) Eddy-Current Detection of Cracks in Reinforced Carbon/Carbon; 18) Apparent Thermal Conductivity of Multilayer Insulation; 19) Optimizing Misch-Metal Compositions in Metal Hydride Anodes; 20) Device for Sampling Surface Contamination; 21) Probabilistic Failure Assessment for Fatigue; 22) Probabilistic Fatigue and Flaw-Propagation Analysis; 23) Windows Program for Driving the TDU-850 Printer; 24) Subband/Transform MATLAB Functions for Processing Images; 25) Computing Equilibrium Chemical Compositions; 26) Program Processes Thermocouple Readings; 27) ICAN-Second-Generation Integrated Composite Analyzer; 28) Integrated Composite Analyzer with Damping Capabilities; 29) Computing Efficiency of Transfer of Microwave Power; 30) Program Calculates Power Demands of Electronic Designs; 31) Cost-Estimation Program; 32) Program Estimates Areas Required by Electronic Designs; 33) Program to Balance Mapped Turbopump Assemblies; 34) BiblioTech; 35) Controlling Mirror Tilt With a Bimorph Actuator; 36) Burst-Disk Device Simulates Effect of Pyrotechnic Device; 37) Bearing-Mounting Concept Accommodates Thermal Expansion; 38) Parallel-Plate Acoustic Absorbers for Hot Environments; 39) Adjustable-Length Strut Withstands Large Cyclic Loads; 40) Tool Indicates Contact Angles in Bearing Raceways; 41) Gravity Slides With Magnetic Braking; 42) High-Torque, Lightweight, Pneumatically Driven Wrench for Small Spaces; 43) Device for Testing Compatibility of an O-Ring; 44) Magnetic Heat Pump Containing Flow Diverters; 45) Variable-Tilt Helicopter Rotor Mast; 46) "Beach-Ball" Robotic Rovers; 47) Apparatus Would Measure Temperatures of Ball Bearings; 48) Flexible Borescope for Inspecting Ducts; 49) Texturing Copper To Reduce Secondary Emission of Electrons; 50) Automated Laser Cutting in Three Dimensions; 51) Algorithm Helps Monitor Engine Operation; 52) Flexible Revision of Data-Processing Communications; 53) Software for Managing the Use of Land; 54) Thermal Strap Increases Cryocooling Efficiency; 55) Reversible Nut With Engagement Indication; 56) Control Algorithms for Kinematically Redundant Manipulators; 57) Computed Hydrogen-Flow Splits in a Rocket Engine; 58) Pressure and Thermal Modeling of Rocket Launches; 59) Field of View of a Spacecraft Antenna: Analysis and Software; 60) Digital Controller for Laser-Beam-Steering Subsystem; 61) More About Beam-Steering Subsystem for Laser Communication; 62) Digital Controller for Laser-Beam-Steering Subsystem: Part 2; 63) Interface Circuit Board for Space-Shuttle Communications; 64) Automated Planning of Spacecraft Telecommunications; 65) Artifacts of Spectral Analysis of Instrument Readings; 66) Neural-Network Controller for Vibration Suppression; 67) Adaptive Finite-Element Computation in Fracture Mechanics; 68) Attitude Control for the Cassini Spacecraft; 69) Analytical Model for Fluid Dynamics in a Microgravity Environment; 70) Study of Rocket-Engine Joints Bonded by NVCU/NARloy-Z; 71) Improved Silicon Nitride for Advanced Heat Engines; 72) Parameters for Welding Aluminum/Lithium Alloys; 73) Lightweight Composite Intertank Structure; 74) Foil Patches Seal Small Vacuum Leaks; 75) Data Base on Cables and Connectors; 76) Effect of Clock Mode on Radiation Hardnessf an ADC; and 77) Fault-Tolerant Control for a Robotic Inspection System.

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Conference on Advanced Technology for Future Space Systems, Hampton, Va., May 8-10, 1979, Technical Papers

Propulsion systems for spacecraft, satellite communications technology, the design of large light-weight erectable structures for assembly in space, electronics and information processing for spacecraft, and self-diagnostic, fault-tolerant controls based on high memory and processing capabilities are discussed. Topics of the papers include the design of large delta wings for earth-to-orbit transports, dual-fuel propulsion units, magnetoplasmadynamic thrusters, heating rates on blunt-nosed bodies at various angles of attack, remote manipulators for space assembly tasks, solar electric propulsion for planetary missions, deployable space platforms with multiple payloads, the design of large offset-fed antennas, a nonlinear stress-strain relationship for metallic meshes, and adaptive sensors for spacecraft.

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Design alternatives for process group membership and multicast

Process groups are a natural tool for distributed programming, and are increasingly important in distributed computing environments. However, there is little agreement on the most appropriate semantics for process group membership and group communication. These issues are of special importance in the Isis system, a toolkit for distributed programming. Isis supports several styles of process group, and a collection of group communication protocols spanning a range of atomicity and ordering properties. This flexibility makes Isis adaptable to a variety of applications, but is also a source of complexity that limits performance. This paper reports on a new architecture that arose from an effort to simplify Isis process group semantics. Our findings include a refined notion of how the clients of a group should be treated, what the properties of a multicast primitive should be when systems contain large numbers of overlapping groups, and a new construct called the casuality domain. As an illustration, we apply the architecture to the problem of converting processes into fault-tolerant process groups in a manner that is 'transparent' to other processes in the system.

Birman, Kenneth P.↗

NASA Tech Briefs, November 2007

Topics include: Wireless Measurement of Contact and Motion Between Contact Surfaces; Wireless Measurement of Rotation and Displacement Rate; Portable Microleak-Detection System; Free-to-Roll Testing of Airplane Models in Wind Tunnels; Cryogenic Shrouds for Testing Thermal-Insulation Panels; Optoelectronic System Measures Distances to Multiple Targets; Tachometers Derived From a Brushless DC Motor; Algorithm-Based Fault Tolerance for Numerical Subroutines; Computational Support for Technology- Investment Decisions; DSN Resource Scheduling; Distributed Operations Planning; Phase-Oriented Gear Systems; Freeze Tape Casting of Functionally Graded Porous Ceramics; Electrophoretic Deposition on Porous Non- Conductors; Two Devices for Removing Sludge From Bioreactor Wastewater; Portable Unit for Metabolic Analysis; Flash Diffusivity Technique Applied to Individual Fibers; System for Thermal Imaging of Hot Moving Objects; Large Solar-Rejection Filter; Improved Readout Scheme for SQUID-Based Thermometry; Error Rates and Channel Capacities in Multipulse PPM; Two Mathematical Models of Nonlinear Vibrations; Simpler Adaptive Selection of Golomb Power-of- Two Codes; VCO PLL Frequency Synthesizers for Spacecraft Transponders; Wide Tuning Capability for Spacecraft Transponders; Adaptive Deadband Synchronization for a Spacecraft Formation; Analysis of Performance of Stereoscopic-Vision Software; Estimating the Inertia Matrix of a Spacecraft; Spatial Coverage Planning for Exploration Robots; and Increasing the Life of a Xenon-Ion Spacecraft Thruster.

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Fault Injection and Monitoring Capability for a Fault-Tolerant Distributed Computation System

The Configurable Fault-Injection and Monitoring System (CFIMS) is intended for the experimental characterization of effects caused by a variety of adverse conditions on a distributed computation system running flight control applications. A product of research collaboration between NASA Langley Research Center and Old Dominion University, the CFIMS is the main research tool for generating actual fault response data with which to develop and validate analytical performance models and design methodologies for the mitigation of fault effects in distributed flight control systems. Rather than a fixed design solution, the CFIMS is a flexible system that enables the systematic exploration of the problem space and can be adapted to meet the evolving needs of the research. The CFIMS has the capabilities of system-under-test (SUT) functional stimulus generation, fault injection and state monitoring, all of which are supported by a configuration capability for setting up the system as desired for a particular experiment. This report summarizes the work accomplished so far in the development of the CFIMS concept and documents the first design realization.

Torres-Pomales, Wilfredo↗

The environmental control and life support system advanced automation project. Phase 1: Application evaluation

The Environmental Control and Life Support System (ECLSS) is a Freedom Station distributed system with inherent applicability to advanced automation primarily due to the comparatively large reaction times of its subsystem processes. This allows longer contemplation times in which to form a more intelligent control strategy and to detect or prevent faults. The objective of the ECLSS Advanced Automation Project is to reduce the flight and ground manpower needed to support the initial and evolutionary ECLS system. The approach is to search out and make apparent those processes in the baseline system which are in need of more automatic control and fault detection strategies, to influence the ECLSS design by suggesting software hooks and hardware scars which will allow easy adaptation to advanced algorithms, and to develop complex software prototypes which fit into the ECLSS software architecture and will be shown in an ECLSS hardware testbed to increase the autonomy of the system. Covered here are the preliminary investigation and evaluation process, aimed at searching the ECLSS for candidate functions for automation and providing a software hooks and hardware scars analysis. This analysis shows changes needed in the baselined system for easy accommodation of knowledge-based or other complex implementations which, when integrated in flight or ground sustaining engineering architectures, will produce a more autonomous and fault tolerant Environmental Control and Life Support System.

Dewberry, Brandon S.↗

Performance and economy of a fault-tolerant multiprocessor

The FTMP (Fault-Tolerant Multiprocessor) is one of two central aircraft fault-tolerant architectures now in the prototype phase under NASA sponsorship. The intended application of the computer includes such critical real-time tasks as 'fly-by-wire' active control and completely automatic Category III landings of commercial aircraft. The FTMP architecture is briefly described and it is shown that it is a viable solution to the multi-faceted problems of safety, speed, and cost. Three job dispatch strategies are described, and their results with respect to job-starting delay are presented. The first strategy is a simple First-Come-First-Serve (FCFS) job dispatch executive. The other two schedulers are an adaptive FCFS and an interrupt driven scheduler. Three failure modes are discussed, and the FTMP survival probability in the face of random hard failures is evaluated. It is noted that the hourly cost of operating two FTMPs in a transport aircraft can be as little as one-to-two percent of the total flight-hour cost of the aircraft.

Lala, J. H.↗

Proceedings of the Sixth NASA Langley Formal Methods (LFM) Workshop

Today's verification techniques are hard-pressed to scale with the ever-increasing complexity of safety critical systems. Within the field of aeronautics alone, we find the need for verification of algorithms for separation assurance, air traffic control, auto-pilot, Unmanned Aerial Vehicles (UAVs), adaptive avionics, automated decision authority, and much more. Recent advances in formal methods have made verifying more of these problems realistic. Thus we need to continually re-assess what we can solve now and identify the next barriers to overcome. Only through an exchange of ideas between theoreticians and practitioners from academia to industry can we extend formal methods for the verification of ever more challenging problem domains. This volume contains the extended abstracts of the talks presented at LFM 2008: The Sixth NASA Langley Formal Methods Workshop held on April 30 - May 2, 2008 in Newport News, Virginia, USA. The topics of interest that were listed in the call for abstracts were: advances in formal verification techniques; formal models of distributed computing; planning and scheduling; automated air traffic management; fault tolerance; hybrid systems/hybrid automata; embedded systems; safety critical applications; safety cases; accident/safety analysis.

Rozier, Kristin Yvonne↗

Development and Evaluation of Fault-Tolerant Flight Control Systems

The research is concerned with developing a new approach to enhancing fault tolerance of flight control systems. The original motivation for fault-tolerant control comes from the need for safe operation of control elements (e.g. actuators) in the event of hardware failures in high reliability systems. One such example is modem space vehicle subjected to actuator/sensor impairments. A major task in flight control is to revise the control policy to balance impairment detectability and to achieve sufficient robustness. This involves careful selection of types and parameters of the controllers and the impairment detecting filters used. It also involves a decision, upon the identification of some failures, on whether and how a control reconfiguration should take place in order to maintain a certain system performance level. In this project new flight dynamic model under uncertain flight conditions is considered, in which the effects of both ramp and jump faults are reflected. Stabilization algorithms based on neural network and adaptive method are derived. The control algorithms are shown to be effective in dealing with uncertain dynamics due to external disturbances and unpredictable faults. The overall strategy is easy to set up and the computation involved is much less as compared with other strategies. Computer simulation software is developed. A serious of simulation studies have been conducted with varying flight conditions.

Song, Yong D.↗

NASA Tech Briefs, October 2011

Topics covered include: Laser Truss Sensor for Segmented Telescope Phasing; Qualifications of Bonding Process of Temperature Sensors to Deep-Space Missions; Optical Sensors for Monitoring Gamma and Neutron Radiation; Compliant Tactile Sensors; Cytometer on a Chip; Measuring Input Thresholds on an Existing Board; Scanning and Defocusing Properties of Microstrip Reflectarray Antennas; Cable Tester Box; Programmable Oscillator; Fault-Tolerant, Radiation-Hard DSP; Sub-Shot Noise Power Source for Microelectronics; Asynchronous Message Service Reference Implementation; Zero-Copy Objects System; Delay and Disruption Tolerant Networking MACHETE Model; Contact Graph Routing; Parallel Eclipse Project Checkout; Technique for Configuring an Actively Cooled Thermal Shield in a Flight System; Use of Additives to Improve Performance of Methyl Butyrate-Based Lithium-Ion Electrolytes; Li-Ion Cells Employing Electrolytes with Methyl Propionate and Ethyl Butyrate Co-Solvents; Improved Devices for Collecting Sweat for Chemical Analysis; Tissue Photolithography; Method for Impeding Degradation of Porous Silicon Structures; External Cooling Coupled to Reduced Extremity Pressure Device; A Zero-Gravity Cup for Drinking Beverages in Microgravity; Co-Flow Hollow Cathode Technology; Programmable Aperture with MEMS Microshutter Arrays; Polished Panel Optical Receiver for Simultaneous RF/Optical Telemetry with Large DSN Antennas; Adaptive System Modeling for Spacecraft Simulation; Lidar-Based Navigation Algorithm for Safe Lunar Landing; Tracking Object Existence From an Autonomous Patrol Vehicle; Rad-Hard, Miniaturized, Scalable, High-Voltage Switching Module for Power Applications; and Architecture for a 1-GHz Digital RADAR.

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Development of the Orion Crew-Service Module Umbilical Retention and Release Mechanism

The Orion CSM umbilical retention and release mechanism supports and protects all of the cross-module commodities between the spacecrafts crew and service modules. These commodities include explosive transfer lines, wiring for power and data, and flexible hoses for ground purge and life support systems. The mechanism employs a single separation interface which is retained with pyrotechnically actuated separation bolts and supports roughly two dozen electrical and fluid connectors. When module separation is commanded, either for nominal on-orbit CONOPS or in the event of an abort, the mechanism must release the separation interface and sever all commodity connections within milliseconds of command receipt. There are a number of unique and novel aspects of the design solution developed by the Orion mechanisms team. The design is highly modular and can easily be adapted to other vehiclesmodules and alternate commodity sets. It will be flight tested during Orions Exploration Flight Test 1 (EFT-1) in 2014, and the Orion team anticipates reuse of the design for all future missions. The design packages fluid, electrical, and ordnance disconnects in a single separation interface. It supports abort separations even in cases where aerodynamic loading prevents the deployment of the umbilical arm. Unlike the Apollo CSM umbilical which was a destructive separation device, the Orion design is resettable and flight units can be tested for separation performance prior to flight.Initial development testing of the mechanisms separation interface resulted in binding failures due to connector misalignments. The separation interface was redesigned with a robust linear guide system, and the connector separation and boom deployment were separated into two discretely sequenced events. These changes addressed the root cause of the binding failure by providing better control of connector alignment. The new design was tuned and validated analytically via Monte Carlo simulation. The analytical validation was followed by a repeat of the initial test suite plus test cases at thermal extremes and test cases with imposed mechanical failures demonstrating fault tolerance. The mechanism was then exposed to the qualification vibration environment. Finally, separation testing was performed at full speed with live ordnance.All tests of the redesigned mechanism resulted in successful separation of the umbilical interface with adequate force margins and timing. The test data showed good agreement with the predictions of the Monte Carlo simulation. The simulation proved invaluable due to the number of variables affecting the separation and the uncertainty associated with each. The simulation allowed for rapid assessment of numerous trades and contingency scenarios, and can be easily reconfigured for varying commodity sets and connector layouts.

Separation↗