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NASA NTRS2017

Flight Tests of a Remaining Flying Time Prediction System for Small Electric Aircraft in the Presence of Faults

This paper addresses the problem of building trust in the online prediction of a battery powered aircraft's remaining flying time. A series of flight tests is described that make use of a small electric powered unmanned aerial vehicle (eUAV) to verify the performance of the remaining flying time prediction algorithm. The estimate of remaining flying time is used to activate an alarm when the predicted remaining time is two minutes. This notifies the pilot to transition to the landing phase of the flight. A second alarm is activated when the battery charge falls below a specified limit threshold. This threshold is the point at which the battery energy reserve would no longer safely support two repeated aborted landing attempts. During the test series, the motor system is operated with the same predefined timed airspeed profile for each test. To test the robustness of the prediction, half of the tests were performed with, and half were performed without, a simulated powertrain fault. The pilot remotely engages a resistor bank at a specified time during the test flight to simulate a partial powertrain fault. The flying time prediction system is agnostic of the pilot's activation of the fault and must adapt to the vehicle's state. The time at which the limit threshold on battery charge is reached is then used to measure the accuracy of the remaining flying time predictions. Accuracy requirements for the alarms are considered and the results discussed.

Hogge, Edward F.↗

NASA NTRS2017

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing

The NASA Orion Multi-Purpose Crew Vehicle (MPCV), comprised of the Service Module, the Crew Module, and the Launch Abort System, is the next generation human spacecraft designed and built for deep space exploration. Orion will launch on NASAs new heavy-lift rocket, the Space Launch System. The European Space Agency (ESA) is responsible for providing the propulsion sub-assembly of the Service Module to NASA, called the European Service Module (ESM). The ESM is being designed and built by Airbus Safran Launchers for ESA. Traditionally, NASA has utilized reverberant acoustic testing for qualification of spaceflight hardware. The ESM Structural Test Article (E-STA) was tested at the NASA Plum Brook Stations (PBS) Reverberant Acoustic Test Facility in April-May 2016. However, Orion is evaluating an alternative acoustic test method, using direct field acoustic excitation, for the MPCVs Service Module and Crew Module. Lockheed Martin is responsible for the Orion proof-of-concept direct field acoustic test program. The E-STA was exposed to direct field acoustic testing at NASA PBS in February 2017. This paper compares the dynamic response of the E-STA structure and its components to both the reverberant and direct field acoustic test excitations. Advantages and disadvantages of direct field acoustic test excitation method are discussed.

Acoustics↗

NASA NTRS2017

Digital Human Modeling

The development of models to represent human characteristics and behaviors in human factors is broad and general. The term "model" can refer to any metaphor to represent any aspect of the human; it is generally used in research to mean a mathematical tool for the simulation (often in software, which makes the simulation digital) of some aspect of human performance and for the prediction of future outcomes. This section is restricted to the application of human models in physical design, e.g., in human factors engineering. This design effort is typically human interface design, and the digital models used are anthropometric. That is, they are visual models that are the physical shape of humans and that have the capabilities and constraints of humans of a selected population. They are distinct from the avatars used in the entertainment industry (movies, video games, and the like) in precisely that regard: as models, they are created through the application of data on humans, and they are used to predict human response; body stresses workspaces. DHM enable iterative evaluation of a large number of concepts and support rapid analysis, as compared with use of physical mockups. They can be used to evaluate feasibility of escape of a suited astronaut from a damaged vehicle, before launch or after an abort (England, et al., 2012). Throughout most of human spaceflight, little attention has been paid to worksite design for ground workers. As a result of repeated damage to the Space Shuttle which adversely affected flight safety, DHM analyses of ground assembly and maintenance have been developed over the last five years for the design of new flight systems (Stambolian, 2012, Dischinger and Dunn Jackson, 2014). The intent of these analyses is to assure the design supports the work of the ground crew personnel and thereby protect the launch vehicle. They help the analyst address basic human factors engineering questions: can a worker reach the task site from the work platform provided; can she or he see the task site; can she or he control tools, which, if dropped, might damage the system? Figure 7.3.1 provides an example of such analysis for a future NASA launch vehicle. [figure 7.3.1 here] In-space systems for operation by astronauts have long been targets for DHM analysis, given the focus on mission success and concerns for astronaut safety. Figure 7.3.2 illustrates the analysis of the design to support astronaut tasks for an International Space Station glovebox. [Figure 7.3.2 here] Use by

Dischinger, H. Charles, Jr.↗

NASA NTRS2018

A Reliability Comparison of Classical and Stochastic Thickness Margin Approaches to Address Material Property Uncertainties for the Orion Heat Shield

The Orion Thermal Protection System (TPS) margin process uses a root-sum-square approach with branches addressing trajectory, aerothermodynamics, and material response uncertainties in ablator thickness design. The material response branch applies a bondline temperature reduction between the Avcoat ablator and EA9394 adhesive by 60 C (108 F) from its peak allowed value of 260 C (500 F). This process is known as the Bond Line Temperature Material Margin (BTMM) and is intended to cover material property and performance uncertainties. The value of 60 C (108 F) is a constant, applied at any spacecraft body location and for any trajectory. By varying only material properties in a random (monte carlo) manner, the perl-based script mcCHAR is used to investigate the confidence interval provided by the BTMM. In particular, this study will look at various locations on the Orion heat shield forebody for a guided and an abort (ballistic) trajectory.

margins↗

NASA NTRS2018

A Reliability Comparison of Classical and Stochastic Thickness Margin Approaches to Address Material Property Uncertainties for the Orion Heat Shield

The Orion Thermal Protection System (TPS) margin process uses a root-sum-square approach with branches addressing trajectory, aerothermodynamics, and material response uncertainties in ablator thickness design. The material response branch applies a bond line temperature reduction between the Avcoat ablator and EA9394 adhesive by 60 C (108 F) from its peak allowed value of 260 C (500 F). This process is known as the Bond Line Temperature Material Margin (BTMM) and is intended to cover material property and performance uncertainties. The value of 60 C (108 F) is a constant, applied at any spacecraft body location and for any trajectory. By varying only material properties in a random (monte carlo) manner, the perl-based script mcCHAR is used to investigate the confidence interval provided by the BTMM. In particular, this study will look at various locations on the Orion heat shield forebody for a guided and an abort (ballistic) trajectory.

FIAT↗

NASA NTRS2018

Orion's Powered Flight Guidance Burn Options for Near Term Exploration Missions

NASA's Orion exploration spacecraft will fly more demanding mission profiles than previous NASA human flight spacecraft. Missions currently under development are destined for cislunar space. The EM-1 mission will fly unmanned to a Distant Retrograde Orbit (DRO) around the Moon. EM-2 will fly astronauts on a mission to the lunar vicinity. To fly these missions, Orion requires powered flight guidance that is more sophisticated than the orbital guidance flown on Apollo and the Space Shuttle. Orion's powered flight guidance software contains five burn guidance options. These five options are integrated into an architecture based on a proven shuttle heritage design, with a simple closed-loop guidance strategy. The architecture provides modularity, simplicity, versatility, and adaptability to future, yet-to-be-defined, exploration mission profiles. This paper provides a summary of the executive guidance architecture and details the five burn options to support both the nominal and abort profiles for the EM-1 and EM-2 missions.

Fill, Thomas↗

NASA NTRS2018

Orion Powered Flight Guidance Burn Options for Near Term Exploration

Fill, Tom↗

NASA NTRS2018

PEG Enhancement for EM1 and EM2+ Missions

NASA is currently building the Space Launch System (SLS) Block-1 launch vehicle for the Exploration Mission 1 (EM-1) test flight. The next evolution of SLS, the Block-1B Exploration Mission 2 (EM-2), is currently being designed. The Block-1 and Block-1B vehicles will use the Powered Explicit Guidance (PEG) algorithm. Due to the relatively low thrust-to-weight ratio of the Exploration Upper Stage (EUS), certain enhancements to the Block-1 PEG algorithm are needed to perform Block-1B missions. In order to accommodate mission design for EM-2 and beyond, PEG has been significantly improved since its use on the Space Shuttle program. The current version of PEG has the ability to switch to different targets during Core Stage (CS) or EUS flight, and can automatically reconfigure for a single Engine Out (EO) scenario, loss of communication with the Launch Abort System (LAS), and Inertial Navigation System (INS) failure. The Thrust Factor (TF) algorithm uses measured state information in addition to a priori parameters, providing PEG with an improved estimate of propulsion information. This provides robustness against unknown or undetected engine failures. A loft parameter input allows LAS jettison while maximizing payload mass. The current PEG algorithm is now able to handle various classes of missions with burn arcs much longer than were seen in the shuttle program. These missions include targeting a circular LEO orbit with a low-thrust, long-burn-duration upper stage, targeting a highly eccentric Trans-Lunar Injection (TLI) orbit, targeting a disposal orbit using the low-thrust Reaction Control System (RCS), and targeting a hyperbolic orbit. This paper will describe the design and implementation of the TF algorithm, the strategy to handle EO in various flight regimes, algorithms to cover off-nominal conditions, and other enhancements to the Block-1 PEG algorithm. This paper illustrates challenges posed by the Block-1B vehicle, and results show that the improved PEG algorithm is capable for use on the SLS Block 1-B vehicle as part of the Guidance, Navigation, and Control System.

Von der Porten, Paul↗

NASA NTRS2018

Mitigation of Electrostatic Hazards on Spacecraft

Spacecraft are complex systems operating in challenging environments that require customized testing procedures designed to mitigate the unique hazards of a space launch environment. As an example of those testing procedures, we describe the test methodology and recommendations developed to mitigate electrostatic discharges that could have triggered an explosion of the Space Shuttle during launch, return to launch site, abort after one orbit, or during normal landing.

Calle, C. I.↗

NASA NTRS2018

Design Considerations for a Variable Autonomy Executive for UAS in the NAS

This paper describes research targeted towards an autonomy executive (AOS) for UAS in the National Air Space (NAS). The project goal is to incrementally provide the knowledge and intelligence onboard a UAS to safely fly in the National Air Space, eventually autonomous from remote human ground crews and communicating directly with air traffic control. Longer-term, the goal is to provide the capability for pilotless air vehicles such as air taxis that will be key for new transportation concepts such as air mobility-on-demand. For both of these targeted applications, AOS is incorporating artificial intelligence capabilities that operationally meet human pilot competencies. Even when autonomy is achieved from a remote human ground crew, AOS will have variable degrees of autonomy with respect to air traffic control (ATC), just as human pilots do now. AOS has the capability of interacting in natural language with ATC, as well as through data link protocols. AOS can adapt to varying levels of autonomy and control directed by ATC in standard and relaxed FAA phraseology- from being vectored moment by moment, to accepting broad directives such as following a specified aircraft or sighting and avoiding traffic. AOS can autonomously manage contingencies such as vehicle systems degradations and failures. It incorporates a decision maker that takes information from multiple diagnostic reasoners, disambiguates (if needed) sensor results to specific failures using active mode changes, then projects forward the impact of the degradation on the nominal plan. If the nominal plan is no longer viable, then alternative plans are formulated, and subsequently selected and executed, including abort options.

Lowry, Michael↗

NASA NTRS2018

Remaining Flying Time Prediction Implementing Battery Prognostics Framework for Electric UAV's

In this paper the problem of building trust in the online safety prediction of an fixed wing small electric unmanned aerial vehicles (e-UAV) for remaining flying time is addressed. A series of flight tests are described to verify the performance of the remaining flying time prediction algorithm. The estimate of remaining flying time is used to activate an alarm when the predicted remaining time falls below a threshold of two minutes. This updates the pilot to transition to the landing sequence of the flight profile. A second alarm is activated when the battery state of charge (SOC) falls below a specified safety limit threshold. This SOC threshold is the point at which the battery energy reserve would no longer safely support enough aborted landing attempts. During the test flights, the motor system is operated with the same predefined timed airspeed profile for each test. To test the robustness of the developed prediction algorithm, partial tests were performed with and remaining were performed without a simulated power train fault. To simulate a partial power train fault in the e-UAV the pilot engages a resistor bank at a specified time during the test flight. The flying time prediction system is agnostic of the pilot's activation of the fault and must adapt to the vehicle's state. The time at which the limit threshold on battery SOC is reached, it is then used to measure the accuracy of the remaining flying time predictions. This is demonstrated through comparing results from two battery models being developed. Accuracy requirements for the alarms are considered and the results discussed.

Kulkarni, Chetan↗

NASA NTRS2018

Development and Qualification of the Primary Structure of the Orion European Service Module

This paper presents an overview of the development and qualification test campaign for the primary structure of the European Service Module of ORION, the NASA spacecraft which will serve the future human exploration missions to the Moon, Mars and beyond. Under an agreement between NASA and ESA, the ORION will be powered by a European Service Module (ESM), providing also water and oxygen for astronauts' life sustainability. The development and qualification of the European Service Module (ESM) is under ESA responsibility with Airbus Defense and Space as the prime contractor. Thales Alenia Space Italia is responsible for design development, manufacturing, assembly and qualification of the Structure subsystem. The European Service Module, installed onto the launch adapter, shall support the crew module with its adapter and a launch abort system. It shall sustain: - A combination of global and local launch loads during lift off and ascent phases, - On orbit loads induced by engine firing for orbital transfers and attitude control. The ESM structure is based on a core made of Composite Fiber Reinforced Polymer (CFRP) sandwich panels complemented by aluminum alloy platforms, longerons and secondary structures. A development campaign has been implemented in order to define and validate composite parts' strength allowable values for design: coupon tests at material level, test at component level up to breadboards tests performed on main structural components (composite to metallic joints, and at panels' discontinuities). An incremental approach as defined in [1] has been followed. A qualification static test campaign at primary structure assembly level has been implemented in order to validate the design against static stiffness and ultimate strength as well as to correlate the structural Finite Element Model (FEM) used for sizing and confirm the margins of safety. The tests have been performed successfully by Thales Alenia Space Italia (TAS-I) on two flight representative structural models (STA1, STA2), in Turin facilities (Italy) between August 2015 and March 2017, with engineering support of technical representatives from Airbus, ESA, NASA and LMCO. The main development and qualification test activities and associated results are presented and discussed in the paper

Structural Testing↗

NASA NTRS2018

Optimization of Second Fault Detection Thresholds to Maximize Mission Probability of Success

In order to support manned spaceflight safety requirements, the Space Launch System (SLS) has defined program-level requirements for key systems to ensure successful operation under single fault conditions. The SLS program has also levied requirements relating to the capability of the Inertial Navigation System to detect a second fault. This detection functionality is required in order to feed abort analysis and ensure crew safety. Increases in navigation state error due to sensor faults in a purely inertial system can drive the vehicle outside of its operational as-designed environmental and performance envelope. As this performance outside of first fault detections is defined and controlled at the vehicle level, it allows for the use of system level margins to increase probability of mission success on the operational edges of the design. A top-down approach is utilized to assess vehicle sensitivity to second sensor faults. A wide range of failure scenarios in terms of both fault magnitude and time is used for assessment. The approach also utilizes a schedule to change fault detection thresholds autonomously. These individual values are optimized along a nominal trajectory in order to maximize probability of mission success in terms of system-level insertion requirements while minimizing the probability of false positives. This paper will describe an approach integrating Genetic Algorithms and Monte Carlo analysis to tune the threshold parameters to maximize vehicle resilience to second fault events over an ascent mission profile. The analysis approach and performance assessment and verification will be presented to demonstrate the applicability of this approach to second fault detection optimization to maximize mission probability of success through taking advantage of existing margin.

Anzalone, Evan J.↗

NASA NTRS2019

Space Launch System Aeroacoustic Wind Tunnel Test Results

Characterization of accurate launch vehicle unsteady aerodynamics is critical for component and secondary structure vibroacoustic design. For the National Aeronautics and Space Administration (NASA) Space Launch System (SLS), aeroacoustic environments have been derived primarily through sub-scale wind tunnel testing. Both optical techniques and high frequency pressure measurements have been utilized across multiple testing facilities and numerous vehicle configurations to develop a range of preliminary and detailed environments. As the vehicle has matured and evolved, the data collected from each subsequent configuration has allowed for comparison studies which isolate the effects of certain outer mold line (OML) features on measured fluctuating pressure levels. This paper presents observations on some of those effects for features which include abort system protuberances, various fairings geometries, interstage flanges, and multibody interactions between a central core and fall away boosters. These features, and the flow conditions produced by them, are broadly applicable to many launch vehicle configurations.

Steva, Thomas B.↗

NASA NTRS2019

A Comparison of Boundary Layer Wind Profilers for Use with Space Launch Vehicles

The United States Air Force (USAF) operates two space launch ranges, the Eastern Range (ER) and the Western Range (WR). The ER is primarily located at the Cape Canaveral Air Force Station (CCAFS) and the WR is located at the Vandenberg Air Force Base (VAFB). Multiple systems are used to measure the atmosphere at both ranges, including a suite of 915-Mhz (megahertz) Doppler Radar Wind Profilers (DRWP). The 915-MHz DRWPs are used to measure winds in the lowest few kilometers of the atmosphere, primarily in the boundary layer. Boundary layer winds are important during launch, and observations of such can be used as input to toxic dispersion and low-level abort trajectory models. However, these 915-MHz systems are nearing the end of their service life and need to be replaced by systems with similar, or greater, capabilities. The USAF funded evaluations of two systems: a 449-MHz DRWP and a Lidar. Both systems were stationed at each range for separate periods of approximately three months from November 2017 through May 2018. The USAF also funded NASA’s Marshall Space Flight Center (MSFC) Natural Environments Branch (NE) to evaluate wind output from the two systems. MSFC NE conducted analysis to demonstrate the system’s wind accuracy relative to measurements from the Automated Meteorological Profiling System (AMPS) (Divers et al., 2000), data availability, and Effective Vertical Resolution (EVR).

Orcutt, John M.↗

NASA NTRS2018

Design Optimisation and Mass Saving of the Structure of the Orion-MPCV European Service Module

This paper presents an overview of the design optimisation measures that have been proposed and analysed in order to reduce the mass of the structure, including the MMOD (Micro-Meteoroid and Orbital Debris) protection system, of the ESM (European Service Module) for the “Orion” MPCV (Multi-Purpose Crew Vehicle). Under an agreement between NASA and ESA, the NASA Orion MPCV for human space exploration missions will be powered by a European Service Module, based on the design and experience of the ATV (Automated Transfer Vehicle). The development and qualification of the European Service Module is managed and implemented by ESA. The ESM prime contractor and system design responsible is Airbus Defence and Space. Thales Alenia Space Italia is responsible for the design and integration of the ESM Structure and MMOD protection system in addition to the Thermal Control System and the Consumable Storage System. The Orion Multi-Purpose Crew Vehicle is a pressurized, crewed spacecraft that transports up to four crew members from the Earth’s surface to a nearby destination or staging point. Orion then brings the crew members safely back to the Earth’s surface at the end of the mission. Orion provides all services necessary to support the crew members while on-board for short duration missions (up to 21 days) or until they are transferred to another orbiting habitat. The ESM supports the crew module from launch through separation prior to re-entry by providing: in-space propulsion capability for orbital transfer, attitude control, and high altitude ascent aborts; water and oxygen/nitrogen needed for a habitable environment; and electrical power generation. In addition, it maintains the temperature of the vehicle's systems and components and offers space for unpressurized cargo and scientific payloads. The ESM has been designed for the first 2 Lunar orbit missions, EM-1 (Exploration mission 1) is an un-crewed flight planned around mid-2020, and EM-2, the first crewed flight, is planned in 2022. At the time where the first ESM is about to be weighted, the predicted mass lies slightly above the initial requirement. For future builds, mass reduction of the Service Module has been considered necessary. This is being investigated, together with other design improvements, in order to consolidate the ESM design and increase possible future missions beyond the first two Orion MPCV missions. The mass saving study has introduced new optimised structural concepts, optimisation of the MMOD protection shields, and optimised redesign of parts for manufacturing through AM (Additive Manufacturing).

Micro-Meteroids and Orbital Debris Protection Syst↗

NASA NTRS2014

A Failure Propagation Modeling Method for Launch Vehicle Safety Assessment

A method has been developed with the objective of making the potentially intractable problem of launch vehicle failure propagation somewhat less intractable. The approach taken is to essentially decouple the potentially multi-stepped propagation process into a series of bi-component transition probabilities. These probabilities are then used within a simple Monte Carlo simulation process through which the more complex behavior evolves. The process is described using a simple model problem and some discussion of enhancements for real-world applications is included. The role of the model within a broader analysis process for assessing abort effectiveness from launch vehicle failure modes is also described.

Lawrence, Scott↗

NASA NTRS2019

Potential Improvements to the Nuclear Safety and Launch Approval Process for Nuclear Reactors Utilized for Space Power and Propulsion Applications

This study examines potential improvements that could be made to the nuclear safety and launch approval process for fission reactors to reduce the associated uncertainties in cost and schedule while continuing to ensure public safety and environmental protection. It concentrates on the launch approval and mission safety of fission power and propulsion applications of nuclear energy. Improvements to the launch approval process for radioisotope power systems (RPSs) are being considered elsewhere but are acknowledged throughout the report. The study considered technical, process, and organizational improvements to the launch approval processes. The study exclusively evaluated reactors that would not be started up prior to achieving a “sufficiently high orbit,” per United Nations (UN) Resolution 47/68.Potential criticality accidents were considered that could occur during a launch failure or abort or during reentry. Numerous scenarios were examined that might involve one or more Earth flybys as well as potential transportation missions that could intentionally return an active, or previously active fission reactor to Earth orbit. The Study Group was guided in its deliberations according to a number of fundamental principles. These included the paramount importance of adequate and appropriate levels of public safety and environmental protection as well as the importance of the inclusion of independent scientific, engineering, and safety reviews of the applications and proposals as a critical part of the process. Also considered was the need for the development of launch approval processes that might be different, depending upon the source of the application for launch approval, whether it be derived as a governmental launch, a commercial launch, or a hybrid/combination of the two. It is clear that all launches of nuclear reactors into space should have similar safety requirements; however, the safety review effort and the details of the analysis that are required should be commensurate with the potential hazards and the actual risk, which may differ based on the reactor design and its intended purpose. Finally, the study aimed at ensuring that whatever processes and procedures are developed should maximize the sufficiency, simplicity, and transparency of the processes. The Study Group reached five Conclusions and makes thirteen Recommendations. The Conclusions and Recommendations presented here are extensions of those presented previously in other studies. This report attempts to add specificity to the actions that need to be taken in order to move forward with successful space fission reactor programs. Without action to address the perceived and real problems in the launch approval process, designers and mission managers will be reluctant to commit the resources necessary to make space fission reactors a reality.

Camp, Allen↗