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X-38 Experimental Controls Laws

X-38 Experimental Control Laws X-38 is a NASA JSC/DFRC experimental flight test program developing a series of prototypes for an International Space Station (ISS) Crew Return Vehicle, often called an ISS "lifeboat." X- 38 Vehicle 132 Free Flight 3, currently scheduled for the end of this month, will be the first flight test of a modem FCS architecture called Multi-Application Control-Honeywell (MACH), originally developed by the Honeywell Technology Center. MACH wraps classical P&I outer attitude loops around a modem dynamic inversion attitude rate loop. The dynamic inversion process requires that the flight computer have an onboard aircraft model of expected vehicle dynamics based upon the aerodynamic database. Dynamic inversion is computationally intensive, so some timing modifications were made to implement MACH on the slower flight computers of the subsonic test vehicles. In addition to linear stability margin analyses and high fidelity 6-DOF simulation, hardware-in-the-loop testing is used to verify the implementation of MACH and its robustness to aerodynamic and environmental uncertainties and disturbances.

Munday, Steve

Metal Coatings

During the Apollo Program, General Magnaplate Corporation developed process techniques for bonding dry lubricant coatings to space metals. The coatings were not susceptible to outgassing and offered enhanced surface hardness and superior resistance to corrosion and wear. This development was necessary because conventional lubrication processes were inadequate for lightweight materials used in Apollo components. General Magnaplate built on the original technology and became a leader in development of high performance metallurgical surface enhancement coatings - "synergistic" coatings, - which are used in applications from pizza making to laser manufacture. Each of the coatings is designed to protect a specific metal or group of metals to solve problems encountered under operating conditions.

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Spinoff 1979

Technology is knowledge, the technical "know-how" employed by a society to produce things that improve the quality of human life. Like other forms of knowledge, it is transferable; once developed, technology can be applied to uses different-and often remote-from the original application. Thus, the technology that NASA has developed in more than two decades of space and aeronautical research constitutes a valuable national resource, a bank of knowledge available for secondary utilization, or "spinoff." NASA mainline programs, by their challenging nature, are particularly demanding of technological advance; meeting their goals has forced extraordinary advancements in virtually every scientific and technological discipline. For that reason, the wealth of aerospace-generated knowledge available for transfer is exceptionally diverse, and much of it is readily applicable to secondary use over a broad spectrum of public needs and conveniences. Through its Congressionally mandated Technology Utilization Program, NASA seeks to promote wider use of this technological resource. The program provides a link between the technology bank and those in either the private or public sectors who might be able to re-use the technology productively. Its aim is to accelerate the transfer process, to bring to the marketplace sooner those spinoffs which might eventually occur in the normal course of events, and to gain thereby more immediate economic benefit in terms of new products and new jobs. The program has been remarkably successful. Since its inception 17 years ago, thousands of spinoff products and processes have emerged. Some of these innovations bring only moderate increments of economic gain or lifestyle improvement, but many others amount to significant public benefits, with economic values often running to millions of dollars. Collectively, spinoffs provide a substantial bonus return on the funds invested in aerospace research. This publication is intended to increase public awareness of the resource that is NASA's technology bank and its potential for further public benefit. It is devoted primarily to the NASA technology transfer process, but in the interests of perspective it also describes related areas of NASA endeavor. Section 1 consists of a resume of NASA's current mainline programs. These programs are producing direct public benefit through direct application of technology; at the same time, they are contributing to indirect benefit-spinoff-by generating new technology which may find secondary application in the future. Section 2 is the focal point of this volume. It contains a representative sampling of spinoff products and processes employed in various avenues of everyday life, and it describes briefly the NASA technology from which these transfers derived. Section 3 details the mechanisms of the technology transfer process, including the means by which NASA seeks to stimulate technology utilization. Also described are NASA's activities in a related area of technology transfer: provision of assistance to agencies interested in exploiting the benefit potential of satellite remote sensing technology.

Haggerty, James J.

NASA's Orbital Space Plane Risk Reduction Strategy

This paper documents the transformation of NASA s Space Launch Initiative (SLI) Second Generation Reusable Launch Vehicle Program under the revised Integrated Space Transportation Plan, announced November 2002. Outlining the technology development approach followed by the original SLI, this paper gives insight into the current risk-reduction strategy that will enable confident development of the Nation s first orbital space plane (OSP). The OSP will perform an astronaut and contingency cargo transportation function, with an early crew rescue capability, thus enabling increased crew size and enhanced science operations aboard the International Space Station. The OSP design chosen for full-scale development will take advantage of the latest innovations American industry has to offer. The OSP Program identifies critical technologies that must be advanced to field a safe, reliable, affordable space transportation system for U.S. access to the Station and low-Earth orbit. OSP flight demonstrators will test crew safety features, validate autonomous operations, and mature thermal protection systems. Additional enabling technologies may be identified during the OSP design process as part of an overall risk-management strategy. The OSP Program uses a comprehensive and evolutionary systems acquisition approach, while applying appropriate lessons learned.

Dumbacher, Dan

Shape optimization of tibial prosthesis components

NASA technology and optimal design methodologies originally developed for the optimization of composite structures (engine blades) are adapted and applied to the optimization of orthopaedic knee implants. A method is developed enabling the shape tailoring of the tibial components of a total knee replacement implant for optimal interaction within the environment of the tibia. The shape of the implant components are optimized such that the stresses in the bone are favorably controlled to minimize bone degradation, to improve the mechanical integrity of the implant/interface/bone system, and to prevent failures of the implant components. A pilot tailoring system is developed and the feasibility of the concept is demonstrated and evaluated. The methodology and evolution of the existing aerospace technology from which this pilot optimization code was developed is also presented and discussed. Both symmetric and unsymmetric in-plane loading conditions are investigated. The results of the optimization process indicate a trend toward wider and tapered posts as well as thicker backing trays. Unique component geometries were obtained for the different load cases.

Saravanos, D. A.

Laserfax

The photo shows an Associated Press technician receiving a photograph prepared by means of a high speed, high resolution facsimile system known as Laserfax, so called because it employs a laser beam to scan the photo being sent. Laser scanning data is converted to electrical signals and transmitted to news bureaus within the Associated Press network via microwave radio or telephone lines. At the other end, another laser sweeps reconverted imagery onto a special, light-sensitive, dry silver paper. The paper is then heat processed to reproduce the photograph. Manufactured by Harris Electronics Systems Inc., Melbourne, Florida, Laserfax incorporates NASA thermal control coating technology developed by Jet Propulsion Laboratory for use on spacecraft antennas; the coatings block absorption of solar radiation which would interfere with the antenna's proper operation. Harris Electronics Systems, originally Radiation, Inc., reused the NASA technology in development of Laserfax. A NASA technical support package provided information about the thermal properties that could be expected of various coatings for the facsimile system's paper rollers; this information served as a design base for the infrared heat source used in developing the photo. Although relatively new, Laserfax is in extensive service. It is manufactured in several models. One of them is the type used by the Associated Press, its news bureaus and affiliated newspapers, radio and television stations. Other models have been sold in large numbers to law enforcement agencies for transmitting high quality fingerprints and identification photos. Laserfax is also in service with the National Weather Service, which converts satellite imagery to weather photographs and relays them to local weather stations, television stations, newspapers and airlines.

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Creep/Rupture Behavior of Melt-Infiltrated SiC/SiC Composites Being Investigated

The failure behavior of melt-infiltrated SiC/SiC ceramic matrix composites is under investigation at the NASA Glenn Research Center as part of NASA's Ultra-Efficient Engine Technology Program. This material was originally developed under the High Speed Research Office's Enabling Propulsion Materials Program. Creep and rupture data provide accelerated testing information to predict material behavior under engine use situations (1500 to 2400 F). This information gives insights into various material development paths to improve composites as well as improve understanding of failure mechanisms. The left figure shows the fracture surface of a CMC material following over 200 hr of testing at 2400 F. This surface demonstrates the kind of fibrous pullout desirable for maximum crack deflection, hence non-brittle failure. Microscopy suggests that creep and rupture of these materials can best be considered as a probabilistic property, rather than a material property. Fiber failure occurs first in isolated regions, while stronger adjacent fibers remain intact. The right figure shows a region where oxide deposits blur and round the fiber images. Because the oxidation kinetics of SiC are well understood, this oxide scale can be used as a measure of the length of time various regions of the composites have been exposed to the environment, hence providing vital information regarding the sequence of failure. The oxide scale in the right figure indicates an early failure of this tow of fibers, whereas adjacent tows remain oxide free, suggesting failure much later in time. The path of various cracks can be followed throughout the composite in this manner, suggesting failure mechanisms.

Hurst, Janet B.

World Wind Tools Reveal Environmental Change

Originally developed under NASA's Learning Technologies program as a tool to engage and inspire students, World Wind software was released under the NASA Open Source Agreement license. Honolulu, Hawaii based Intelesense Technologies is one of the companies currently making use of the technology for environmental, public health, and other monitoring applications for nonprofit organizations and Government agencies. The company saved about $1 million in development costs by using the NASA software.

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Autonomous Navigation for Deep Space Missions

Navigation (determining where the spacecraft is at any given time, controlling its path to achieve desired targets), performed using ground-in- the-loop techniques: (1) Data includes 2-way radiometric (Doppler, range), interferometric (Delta- Differential One-way Range), and optical (images of natural bodies taken by onboard camera) (2) Data received on the ground, processed to determine orbit, commands sent to execute maneuvers to control orbit. A self-contained, onboard, autonomous navigation system can: (1) Eliminate delays due to round-trip light time (2) Eliminate the human factors in ground-based processing (3) Reduce turnaround time from navigation update to minutes, down to seconds (4) React to late-breaking data. At JPL, we have developed the framework and computational elements of an autonomous navigation system, called AutoNav. It was originally developed as one of the technologies for the Deep Space 1 mission, launched in 1998; subsequently used on three other spacecraft, for four different missions. The primary use has been on comet missions to track comets during flybys, and impact one comet.

navigation

Voltage Controller

Power Efficiency Corporation, specifically formed to manufacture and develop products from NASA technology, has a license to a three-phase power factor controller originally developed by Frank Nola, an engineer at Marshall Space Flight Center. Power Efficiency and two major distributors, Performance Control and Edison Power Technologies, use the electronic control boards to assemble three different motor controllers: Power Commander, Performance Controller, and Energy Master. The company Power Factor Controller reduces excessive energy waste in AC induction motors. It is used in industries and applications where motors operate under variable loads, including elevators and escalators, machine tools, intake and exhaust fans, oil wells, conveyors, pumps, die casting, and compressors. Customer lists include companies such as May Department Stores, Caesars Atlantic City, Ford Motors, and American Axle.

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Pilot Development Progress to Demonstrate Electric Thermal Energy Storage (ETES) Using Low-Cost Particles

The rapid growth of future energy demand increases the need to economically store electrical energy over durations up to several days in long-duration energy storage (LDES) applications. LDES can reduce the grid stress for improving the resilience of the grid. The integration of renewable power and storage has several significant and positive impacts including expanding the renewable energy portion of electricity generation, meeting peak-load demand, and coordinating supply and demand. Several energy storage approaches including mechanical, chemical and electrochemical methods are currently deployed or under development. However, LDES requirements pose unique challenges for scalability, energy capacity, and cost. Thermal energy storage (TES) has the ability to store a large capacity of energy with improved site flexibility compared to incumbent LDES technologies (i.e., pumped hydro) and has attracted significant interest. Our development in TES technology using solid particles as the storage medium has shown feasibility and potential in serving LDES purposes. Particle TES has various advantages over commercialized molten nitrate salt TES and has emerged as a promising storage technology originating from Generation 3 concentrating solar power (CSP) development. Stable, inexpensive silica sand produced in the Midwestern U.S. was identified as a suitable storage medium and has been validated through lab heating and cycling tests. We have successfully developed particle TES for bidirectional electric energy storage to broaden the applications for TES beyond CSP technologies and into standalone electric-thermal energy storage (ETES) systems. Key component designs and performance were verified with prototype testing and model simulations. The ETES system uses high-temperature, low-cost particle thermal energy storage coupled with a unique pressurized fluidized bed heat exchanger that supports a high-efficiency, air-Brayton combined power cycle. At times of low energy demand or high renewable production, an electric particle heater heats large quantities of solid particles to high temperatures in excess of 1100 degrees C. The particles are stored in internally insulated silos. At times of high electricity demand, the hot particles are gravity-fed through the heat exchanger where stored thermal energy is transferred to the power cycle working fluid to drive the gas turbine power generation system, thereby converting the thermal energy back into electricity for the grid. The cold particles leaving the heat exchanger are returned to the storage silos by a well-insulated particle conveyor. This ETES technology using particle TES can be sited anywhere and is predicted to be economic and efficient. Moreover, this ETES technology could be co-located with a retired coal or gas plant to leverage existing power generation and grid infrastructure. Our work has focused on the development of each of the key components (e.g., the electric particle heater, particle storage silos, and the particle-to-gas pressurized fluidized bed heat exchanger) through conceptual designs, prototype testing, and computational modeling. These developments demonstrate technological feasibility and are an important step towards the next phase of development of this promising LDES technology. This presentation will show the progress in developing a pilot demonstration of the ETES system on a commercially relevant scale.

25 ENERGY STORAGE

Data Management System

CENTRA 2000 Inc., a wholly owned subsidiary of Auto-trol technology, obtained permission to use software originally developed at Johnson Space Center for the Space Shuttle and early Space Station projects. To support their enormous information-handling needs, a product data management, electronic document management and work-flow system was designed. Initially, just 33 database tables comprised the original software, which was later expanded to about 100 tables. This system, now called CENTRA 2000, is designed for quick implementation and supports the engineering process from preliminary design through release-to-production. CENTRA 2000 can also handle audit histories and provides a means to ensure new information is distributed. The product has 30 production sites worldwide.

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Image Compression Devices

The Rice algorithm is a "lossless" compression algorithm; it takes an image or other data that has been broken down into short strings of digital data, then processes each string mathematically to reduce the amount of memory required to store or transmit them. It is particularly useful in medical, scientific or engineering applications where all data must be preserved. Originally developed at Jet Propulsion Laboratory, the technology is marketed by Advanced Hardware Architectures, a company started by a former employee of the NASA Microelectronics Research Center.

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Precision Heating Process

A heat sealing process was developed by SEBRA based on technology that originated in work with NASA's Jet Propulsion Laboratory. The project involved connecting and transferring blood and fluids between sterile plastic containers while maintaining a closed system. SEBRA markets the PIRF Process to manufacturers of medical catheters. It is a precisely controlled method of heating thermoplastic materials in a mold to form or weld catheters and other products. The process offers advantages in fast, precise welding or shape forming of catheters as well as applications in a variety of other industries.

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Solar Airplanes and Regenerative Fuel Cells

A solar electric aircraft with the potential to "fly forever" has captured NASA's interest, and the concept for such an aircraft was pursued under Aeronautics Environmental Research Aircraft and Sensor Technology (ERAST) project. Feasibility of this aircraft happens to depend on the successful development of solar power technologies critical to NASA's Exploration Initiatives; hence, there was widespread interest throughout NASA to bring these technologies to a flight demonstration. The most critical is an energy storage system to sustain mission power during night periods. For the solar airplane, whose flight capability is already limited by the diffuse nature of solar flux and subject to latitude and time of year constraints, the feasibility of long endurance flight depends on a storage density figure of merit better than 400-600 watt-hr per kilogram. This figure of merit is beyond the capability of present day storage technologies (other than nuclear) but may be achievable in the hydrogen-oxygen regenerative fuel cell (RFC). This potential has led NASA to undertake the practical development of a hydrogen-oxygen regenerative fuel cell, initially as solar energy storage for a high altitude UAV science platform but eventually to serve as the primary power source for NASAs lunar base and other planet surface installations. Potentially the highest storage capacity and lowest weight of any non-nuclear device, a flight-weight RFC aboard a solar-electric aircraft that is flown continuously through several successive day-night cycles will provide the most convincing demonstration that this technology's widespread potential has been realized. In 1998 NASA began development of a closed cycle hydrogen oxygen PEM RFC under the Aeronautics Environmental Research Aircraft and Sensor Technology (ERAST) project and continued its development, originally for a solar electric airplane flight, through FY2005 under the Low Emissions Alternative Power (LEAP) project. Construction of the closed loop system began in 2002 at the NASA Glenn Research Center in Cleveland, Ohio. System checkout was completed, and testing began, in July of 2003. The initial test sequences were done with only a fuel cell or electrolyzer in the test rig. Those tests were used to verify the test apparatus, procedures, and software. The first complete cycles of the fully closed loop, regenerative fuel cell system were successfully completed in the following September. Following some hardware upgrades to increase reactant recirculation flow, the test rig was operated at full power in December 2003 and again in January 2004. In March 2004 a newer generation of fuel cell and electrolyzer stacks was substituted for the original hardware and these stacks were successfully tested at full power under cyclic operation in June of 2004.

Bents, David J.

Why Should Humans Explore a Near Earth Asteroid and What Factors Drive the Medical Risks?

The National Aeronautics and Space Administration (NASA) is currently considering plans for the human exploration of a Near Earth Asteroid (NEA). Reasons for undertaking the human exploration of a NEA include increasing the scientific understanding of the origins of our solar system, and developing technology for the exploration of more distant destinations such as Mars. Most mission scenarios have a duration on the order of several months or a year, most of which is spent in transit to and from the NEA. The choice of a particular NEA destination determines the mission duration and guides the types of exploration activities that can be performed on and near the NEA. NASA s Human Research Program (HRP) has identified short and long-term health risks associated with such missions and begun characterizing the level of risk. Some risk drivers are well known from missions to low Earth orbit and the Moon (e.g., the limited mass, volume, and power available for the medical care system). Other factors emerge as major drivers for NEA missions. Some are fundamental characteristics of the mission parameters (e.g., mission duration, distance) and others are strongly dependent on the specifics of how the mission is implemented (e.g., isolation and confinement). Careful consideration of these factors will be required for safe and effective missions to NEAs.

Kundrot, Craig E.

Portable Inspection

The portable SpectroReflectometer, an instrument developed by AZ Technology, Inc. in partnership with NASA's Kennedy Space Center is now being manufactured and sold as a cost-effective solution to the development of scientific space flight hardware. This technology originated with the efforts to determine the degradation mechanisms of the space environment on space craft materials. AZ Technology's mission is to provide high quality products and services in electro-mechanical-optical design and hardware integration, advanced thermal and optical coatings and materials, and in the development of custom hardware systems for scientific measurements.

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NASA and Blue Origin Collaborative Assessment of Precision Landing Algorithms and Computing

NASA’s Safe and Precise Landing Integrated Capabilities Evolution (SPLICE) project is developing sensor, algorithm, and compute technologies for precision landing and hazard avoidance. These technologies are being tested as an integrated Precision Landing and Hazard Avoidance (PL&HA) system on Blue Origin’s New Shephard suborbital vehicle. A key goal for the computing element of this technology development is to characterize the performance of the SPLICE software workloads on the project’s Descent and Landing Computer (DLC). The DLC is a multi-core processor designed as a surrogate for NASA’s High-Performance Space Computer (HPSC). Measurements of the SPLICE workload performance on the DLC provides NASA insight on how PL&HA capabilities will perform on the HPSC, and guidance on how the SPLICE algorithms can be implemented to best utilize the DLC platform. This insight can also be used to derive requirements to guide trade studies on candidate computing architectures, for use on platforms like Blue Moon. NASA and Blue Origin are collaborating under an agreement to pursue this mutual benefit. Performance metrics collected are based on measurement of common compute resources such as percentage used of memory bandwidth, I/O utilization, interrupt latency, and kernel vs. user space code residency. Where possible existing performance counters and metrics that are part of the operating system kernel are used. As the design has a significant FPGA component, performance counters are identified and instantiated in the fabric to measure DMA performance and interface metrics. Collection of metrics is performed on the DLC with a representative workload that simulates a full landing cycle of the Blue Origin New Shepard vehicle. Consideration is given to the other compute implementations and whether they can run SPLICE algorithms at the same rate and with the same latency as the DLC. One option being considered is the use of a RISC-V soft core instantiated in a radiation resilient FPGA fabric such as the Xilinx KU60. Select algorithms from the SPLICE code will be run for comparison with the DLC. This paper describes how the DLC is instrumented to collect performance measurements of the SPLICE workloads, preliminary results from these measurements, and their implications on SPLICE algorithm implementation. The results of experimentation to derive candidate requirements for architecture trades on a PL&HA computing system are also presented.

computer performance