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NASA NTRS2005

Flexible Models for Solar Sail Control

Solar sails employ a unique form of propulsion, gaining momentum from incident and reflected photons. However, the momentum transferred by an individual photon is extremely small. Consequently, a solar sail must have an extremely large surface area and also be extremely light. The flexibility of the sail then must be considered when designing or evaluating control laws. In this paper, solar sail flexibility and its influence on control effectiveness is considered using idealized two-dimensional models to represent physical phenomena rather than a specific design. Differential equations of motion are derived for a distributed parameter model of a flexible solar sail idealized as a rotating central hub with two opposing flexible booms. This idealization is appropriate for solar sail designs in which the vibrational modes of the sail and supporting booms move together allowing the sail mass to be distributed along the booms in the idealized model. A reduced analytical model of the flexible response is considered. Linear feedback torque control is applied at the central hub. Two translational disturbances and a torque disturbance also act at the central hub representing the equivalent effect of deflecting sail shape about a reference line. Transient simulations explore different control designs and their effectiveness for controlling orientation, for reducing flexible motion and for disturbance rejection. A second model also is developed as a two-dimensional "pathfinder" model to calculate the effect of solar sail shape on the resultant thrust, in-plane force and torque at the hub. The analysis is then extended to larger models using the finite element method. The finite element modeling approach is verified by comparing results from a two-dimensional finite element model with those from the analytical model. The utility of the finite element modeling approach for this application is then illustrated through examples based on a full finite element model.

Weaver Smith, Suzanne↗

NASA NTRS2005

The Plunge Phase of Friction Stir Welding

Torque and plunge force during the initial plunge phase in Friction Stir Welding were measured for a 0.5 inch diameter pin entering a 2219 aluminum alloy plate. Weld structures were preserved for metallographic observation by making emergency stops at various plunge depths. The plunging pin tool is seen to be surrounded by a very fine grained layer of recrystallized metal extending substantially below the bottom of the pin, implying a shear interface in the metal below and not at the tool-metal interface. Torque and plunge force during the initial plunge phase in Friction Stir Welding are calculated from a straight forward model based on a concept to plastic flow in the vicinity of the plunging tool compatible with structural observations. The concept: a disk of weld metal seized to and rotating with the bottom of the pin is squeezed out laterally by the plunge force and extruded upwards in a hollow cylinder around the tool. As the shear surface separating rotating disk from stationary weld metal engulfs fresh metal, the fresh metal is subjected to severe shear deformation, which results in its recrystallization. Encouraging agreement between computations and measured torque and plunge force is obtained.

Nunes, Arthur↗

NASA NTRS2005

Spinning Spacecraft Attitude Estimation Using Markley Variables: Filter Implementation And Results

Attitude estimation is often more difficult for spinning spacecraft than for three-axis stabilized platforms due to the need to follow rapidly-varying state vector elements and the lack of three-axis rate measurements from gyros. The estimation problem simplifies when torques are negligible and nutation has damped out, but the general case requires a sequential filter with dynamics propagation. This paper describes the implementation and test results for an extended Kalman filter for spinning spacecraft attitude and rate estimation based on a novel set of variables suggested in a paper by Markley [AAS93-3301 (referred to hereafter as Markley variables). Markley has demonstrated that the new set of variables provides a superior parameterization for numerical integration of the attitude dynamics for spinning or momentum-biased spacecraft. The advantage is that the Markley variables have fewer rapidly-varying elements than other representations such as the attitude quaternion and rate vector. A filter based on these variables was expected to show improved performance due to the more accurate numerical state propagation. However, for a variety of test cases, it has been found that the new filter, as currently implemented, does not perform significantly better than a quaternion-based filter that was developed and tested in parallel. This paper reviews the mathematical background for a filter based on Markley variables. It also describes some features of the implementation and presents test results. The test cases are based on a mission using magnetometer and Sun sensor data and gyro measurements on two axes normal to the spin axis. The orbit and attitude scenarios and spacecraft parameters are modeled after one of the THEMIS (Time History of Events and Macroscale Interactions during Substorms) probes. Several tests are presented that demonstrate the filter accuracy and convergence properties. The tests include torque-free motion with various nutation angles, large constant-torque attitude slews, sensor misalignments, large initial attitude and rate errors, and cases with low data frequency. It is found that the convergence is rapid, the radius of convergence is large, and the results are reasonably accurate even in the presence of unmodeled perturbations.

Sedlak, Joseph E.↗

NASA NTRS2007

The Prelude to and Aftermath of the Giant Flare of 2004 December 27: Persistent and Pulsed X-ray Properties of SGR 1806-20 from 1993 to 2005

We report on the evolution of key spectral and temporal parameters of SGR 1806-20 prior to and following the highly energetic giant flare of 2004 December 27. Using RXTE, we track the pulse frequency of the SGR and find that the spin-down rate varied erratically in the months before and after the flare. Contrary to the giant flare in SGR 1900+14, we find no evidence for a discrete jump in spin frequency at the time of the December 27th flare (Absolute value of (Delta * upsilon/upsilon) < 5 10 (exp -6)). In the months surrounding the flare, we find a strong correlation between pulsed flux and torque consistent with the model for magnetar magnetosphere electrodynamics proposed. As with the flare in SGR 1900+14, the pulse morphology of SGR 1806-20 changes drastically following the flare. Using Chandra and other publicly available imaging X-ray detector observations, we construct a spectral history of SGR 1806-20 from 1993 to 2005. The usual magnetar persistent emission spectral model of a power law plus a blackbody provides an excellent fit to the data. We confirm the earlier finding of increasing spectral hardness of SGR 1806-20 between 1993 and 2004. However, our results indicate significant differences in the temporal evolution of the spectral hardening. Rather than a direct correlation between torque and spectral hardness, we find evidence for a sudden torque change that preceded a gradual hardening of the energy spectrum on a timescale of years. Interestingly, the spectral hardness, spin-down rate, phase-averaged flux, and pulsed flux of SGR 1806-20 all peak months before the flare epoch.

Woods, Peter M.↗

NASA NTRS1988

Method for spinning up a three-axis controlled spacecraft

A three-axis controlled spacecraft (1), typically a satellite, is spun up about its roll axis (20) prior to firing a motor (2), i.e., a perigee kick motor, to achieve the requisite degree of angular momentum stiffness. Thrusters (21) for imparting rotation about the roll axis (20) are activated in open-loop fashion, typically at less than full duty cycle. Cross-axis torques induced by this rotational motion are compensated for by means of closed control loops for each of the pitch and yaw axes (30, 40, respectively). Each closed control loop combines a prebias torque (72) with torques (75, 74) representative of position and rate feedback information, respectively. A deadband (52) within each closed control loop can be widened during the spinup, to conserve fuel. Position feedback information (75) in each of the control loops is disabled upon saturation of the gyroscope associated with the roll axis (20).

Vorlicek, Preston L.↗

NASA NTRS1992

Spacecraft attitude and velocity control system

A spacecraft attitude and/or velocity control system includes a controller which responds to at least attitude errors to produce command signals representing a force vector F and a torque vector T, each having three orthogonal components, which represent the forces and torques which are to be generated by the thrusters. The thrusters may include magnetic torquer or reaction wheels. Six difference equations are generated, three having the form ##EQU1## where a.sub.j is the maximum torque which the j.sup.th thruster can produce, b.sub.j is the maximum force which the j.sup.th thruster can produce, and .alpha..sub.j is a variable representing the throttling factor of the j.sup.th thruster, which may range from zero to unity. The six equations are summed to produce a single scalar equation relating variables .alpha..sub.j to a performance index Z: ##EQU2## Those values of .alpha. which maximize the value of Z are determined by a method for solving linear equations, such as a linear programming method. The Simplex method may be used. The values of .alpha..sub.j are applied to control the corresponding thrusters.

Paluszek, Michael A.↗

NASA NTRS2003

3-D sprag ratcheting tool

A ratcheting device comprising a driver head assembly which includes at least two 3-D sprag elements positioned within a first groove within the driver head assembly such that at least one of the 3-D sprag elements may lockingly engage the driver head assembly and a mating hub assembly to allow for rotation of the hub assembly in one direction with respect to the driver head assembly. This arrangement allows the ratcheting tool to impart torque in either the clockwise or counterclockwise direction without having to first rotate the ratcheting tool in the direction opposite the direction in which the torque is applied. This arrangement also allows the ratcheting tool to impart torque in either the clockwise or counterclockwise direction while in the neutral position.

Wade, Michael O.↗

NASA NTRS2003

Fastener starter tool

A fastener starter tool includes a number of spring retention fingers for retaining a small part, or combination of parts. The tool has an inner housing, which holds the spring retention fingers, a hand grip, and an outer housing configured to slide over the inner housing and the spring retention fingers toward and away from the hand grip, exposing and opening, or respectively, covering and closing, the spring retention fingers. By sliding the outer housing toward (away from) the hand grip, a part can be released from (retained by) the tool. The tool may include replaceable inserts, for retaining parts, such as screws, and configured to limit the torque applied to the part, to prevent cross threading. The inner housing has means to transfer torque from the hand grip to the insert. The tool may include replaceable bits, the inner housing having means for transferring torque to the replaceable bit.

Chandler, Faith T.↗

NASA NTRS2008

External Tank (ET) Bipod Fitting Bolted Attachment Locking Insert Performance

Following STS-107, the External Tank (ET) Project implemented corrective actions and configuration changes at the ET bipod fitting. Among the corrective actions, the existing bolt lock wire which provided resistance to potential bolt rotation was removed. The lock wire removal was because of concerns with creating voids during foam application and potential for lock wire to become debris. The bolts had been previously lubricated to facilitate assembly but, because of elimination of the lock wire, the ET Project wanted to enable the locking feature of the insert. Thus, the lubrication was removed from bolt threads and instead applied to the washer under the bolt head. Lubrication is necessary to maximize joint pre-load while remaining within the bolt torque specification. The locking feature is implemented by thread crimping in at four places in the insert. As the bolt is torqued into the insert the bolt threads its way past the crimped parts of the insert. This provides the locking of the bolt, as torque is required to loosen the joint after clamping.

Larsen, Curtis E.↗

NASA NTRS2008

Determining Exercise Strength Requirements for Astronaut Critical Mission Tasks: Reaching Under G-Load

The critical mission tasks assessments effort seeks to determine the physical performance requirements that astronauts must meet in order to safely and successfully accomplish lunar exploration missions. These assessments will determine astronaut preflight strength, fitness, and flexibility requirements, and the extent to which exercise and other countermeasures must prevent the physical deconditioning associated with prolonged weightlessness. The purpose is to determine the flexibility and strength that crewmembers must possess in order to reach Crew Exploration Vehicle controls during maneuvers that result in sustained acceleration levels ranging from 3.7G to 7.8G. An industry standard multibody dynamics application was used to create human models representing a 5th percentile female, a 50th percentile male, and a 95th percentile male. The additional mass of a space suit sleeve was added to the reaching arm to account for the influence of the suit mass on the reaching effort. The human model was merged with computer models of a pilot seat and control panel for the Crew Exploration Vehicle. Three dimensional paths were created that guided the human models hand from a starting position alongside its thigh to three control targets: a joystick, a keyboard, and an overhead switch panel. The reaching motion to each target was repeated under four vehicle acceleration conditions: nominal ascent (3.7G), two ascent aborts (5.5G and 7.8G) and lunar reentry (4.6G). Elbow and shoulder joint angular excursions were analyzed to assess range of motion requirements. Mean and peak elbow and shoulder joint torques were determined and converted to equivalent resistive exercise loads to assess strength requirements. Angular excursions for the 50th and 95th percentile male models remained within joint range of motion limits. For the 5th percentile female, both the elbow and the shoulder exceeded range of motion limits during the overhead reach. Elbow joint torques ranged from 10 N-m (nominal ascent) to 60 N-m (ascent abort). Shoulder joint torques ranged from 65 N-m (nominal ascent) to 280 N-m (ascent abort). Maximal equivalent exercise loads reached 30 lb in tricep extension, 9 lb in bicep curl, 110 lb in unilateral pullover and unilateral bench press for nominal conditions (lunar reentry), and 188 lb in unilateral pullover and unilateral bench press. The location of the pilot seat was found to be inadequately located to allow a 5th percentile female to reach the switches on the overhead panel. Elbow strength requirements were found to be well within population norms. Shoulder strength was found to be a limiting factor. Reaching under nominal ascent and lunar reentry conditions was found to require near maximal shoulder strength. Reaching under ascent abort conditions requires shoulder strength well beyond population norms. Pilot seats must adjust to accomodate a 5th percentile female. Exercise countermeasures must maintain maximal pullover and bench press strength to allow pilots to reach and operate controls during lunar reentry. Reaching will not be possible during ascent abort conditions. Flight controls should be built into armrests or flight control must be accomplished by autonomous systems during acceleration exceeding 4.6G.

Schaffner, Grant↗

NASA NTRS2007

SDO Delta H Mode Design and Analysis

While on orbit, disturbance torques on a three axis stabilized spacecraft tend to increase the system momentum, which is stored in the reaction wheels. Upon reaching the predefined momentum capacity (or maximum wheel speed) of the reaction wheel, an external torque must be used to unload the momentum. The purpose of the Delta H mode is to manage the system momentum. This is accomplished by driving the reaction wheels to a target momentum state while the attitude thrusters, which provide an external torque, are used to maintain the attitude. The Delta H mode is designed to meet the mission requirements and implement the momentum management plan. Changes in the requirements or the momentum management plan can lead to design changes in the mode. The momentum management plan defines the expected momentum buildup trend, the desired momentum state and how often the system is driven to the desired momentum state (unloaded). The desired momentum state is chosen based on wheel capacity, wheel configuration, thruster layout and thruster sizing. For the Solar Dynamics Observatory mission, the predefined wheel momentum capacity is a function of the jitter requirements, power, and maximum momentum capacity. Changes in jitter requirements or power limits can lead to changes in the desired momentum state. These changes propagate into the changes in the momentum management plan and therefore the Delta H mode design. This paper presents the analysis and design performed for the Solar Dynamics Observatory Delta H mode. In particular, the mode logic and processing needed to meet requirements is described along with the momentum distribution formulation. The Delta H mode design is validated using the Solar Dynamics Observatory High Fidelity simulator. Finally, a summary of the design is provided along with concluding remarks.

Mason, Paul A.↗

NASA NTRS2008

An Experimental Study of Fretting of Gear Teeth

Experiments were conducted to study fretting of gears. The gears were made from case-carburized AISI 9310 alloy to match the material of a flight actuator gearbox of interest. The objective of the testing was to produce damage representative of that observed on flight hardware. The following correlations and observations were noted. The amplitude of dithering motion very strongly influenced the type and magnitude of damage. Sliding amounts on the order of 30% of the width of the line contact were judged to most readily produce fretting damage. There was observed an incubation period on the order of tens-of-thousands of cycles, and the incubation period was influenced by surface roughness, torque, and the motion extent. Fretting damage could be produced for any of the torques tested, and the severity of damage increased slightly with torque. Gear teeth having surface roughness of 0.7-0.8 micrometer were somewhat more resistant to fretting than were smoother surfaces.

Krantz, Timothy L.↗

NASA NTRS2008

Control System for Bearingless Motor-generator

A control system for an electromagnetic rotary drive for bearingless motor-generators comprises a winding configuration comprising a plurality of individual pole pairs through which phase current flows, each phase current producing both a lateral force and a torque. A motor-generator comprises a stator, a rotor supported for movement relative to the stator, and a control system. The motor-generator comprises a winding configuration supported by the stator. The winding configuration comprises at least three pole pairs through which phase current flows resulting in three three-phase systems. Each phase system has a first rotor reference frame axis current that produces a levitating force with no average torque and a second rotor reference frame axis current that produces torque.

Kascak, Peter E.↗

NASA NTRS2008

Attitude and Translation Control of a Solar Sail Vehicle

A report discusses the ability to control the attitude and translation degrees-of-freedom of a solar sail vehicle by changing its center of gravity. A movement of the spacecraft s center of mass causes solar-pressure force to apply a torque to the vehicle. At the compact core of the solar-sail vehicle lies the spacecraft bus which is a large fraction of the total vehicle mass. In this concept, the bus is attached to the spacecraft by two single degree-of-freedom linear tracks. This allows relative movement of the bus in the sail plane. At the null position, the resulting solar pressure applies no torque to the vehicle. But any deviation of the bus from the null creates an offset between the spacecraft center of mass and center of solar radiation pressure, resulting in a solar-pressure torque on the vehicle which changes the vehicle attitude. Two of the three vehicle degrees of freedom can be actively controlled in this manner. The third, the roll about the sunline, requires a low-authority vane/propulsive subsystem. Translation control of the vehicle is achieved by directing the solar-pressure-induced force in the proper inertial direction. This requires attitude control. Attitude and translation degrees-of-freedom are therefore coupled. A guidance law is proposed, which allows the vehicle to stationkeep at an appropriate point on the inertially-rotating Sun-Earth line. Power requirements for moving the bus are minimal. Extensive software simulations have been performed to demonstrate the feasibility of this concept.

Singh, Gurkirpal↗

NASA NTRS2009

Problems Encountered During the Recertification of the GLORY Solar Array Dual Axis Gimbal Drive Actuators

The Glory observatory is the current incarnation of the Vegetation Canopy Lidar (VCL) mission spacecraft bus. The VCL spacecraft bus, having been cancelled for programmatic reasons in 2000, was nearly integrated when it was put into storage for possible future use. The Glory mission was a suitable candidate for using this spacecraft and in 2006 an effort to recertify the two axis solar array gimbal drive after its extended storage was begun. What was expected to be a simple performance validation of the two dual axis gimbal stepper motors became a serious test, diagnosis and repair task once questions arose on the flight worthiness of the hardware. A significant test program logic flow was developed which identified decisions that could be made based on the results of individual recertification tests. Without disassembling the bi-axial gimbals, beginning with stepper motor threshold voltage measurements and relating these to powered drive torque measurements, both performed at the spacecraft integrator s facility, a confusing picture of the health of the actuators came to light. Tests at the gimbal assembly level and tests of the disassembled actuators were performed by the manufacturer to validate our results and torque discrepancies were noted. Further disassembly to the component level of the actuator revealed the source of the torque loss.

Saltzman, Marc↗

NASA NTRS2009

Determining Spacecraft Reaction Wheel Friction Parameters

Software was developed to characterize the drag in each of the Cassini spacecraft's Reaction Wheel Assemblies (RWAs) to determine the RWA friction parameters. This tool measures the drag torque of RWAs for not only the high spin rates (greater than 250 RPM), but also the low spin rates (less than 250 RPM) where there is a lack of an elastohydrodynamic boundary layer in the bearings. RWA rate and drag torque profiles as functions of time are collected via telemetry once every 4 seconds and once every 8 seconds, respectively. Intermediate processing steps single-out the coast-down regions. A nonlinear model for the drag torque as a function of RWA spin rate is incorporated in order to characterize the low spin rate regime. The tool then uses a nonlinear parameter optimization algorithm based on the Nelder-Mead simplex method to determine the viscous coefficient, the Dahl friction, and the two parameters that account for the low spin-rate behavior.

Sarani, Siamak↗

NASA NTRS2010

A Constant-Force Resistive Exercise Unit

A constant-force resistive exercise unit (CFREU) has been invented for use in both normal gravitational and microgravitational environments. In comparison with a typical conventional exercise machine, this CFREU weighs less and is less bulky: Whereas weight plates and associated bulky supporting structures are used to generate resistive forces in typical conventional exercise machines, they are not used in this CFREU. Instead, resistive forces are generated in this CFREU by relatively compact, lightweight mechanisms based on constant-torque springs wound on drums. Each such mechanism is contained in a module, denoted a resistive pack, that includes a shaft for making a torque connection to a cable drum. During a stroke of resistive exercise, the cable is withdrawn from the cable drum against the torque exerted by the resistance pack. The CFREU includes a housing, within which can be mounted one or more resistive pack(s). The CFREU also includes mechanisms for engaging any combination of (1) one or more resistive pack(s) and (2) one or more spring(s) within each resistive pack to obtain a desired level of resistance.

Colosky, Paul↗

NASA NTRS2010

Control system for bearingless motor-generator

Kascak, Peter E.↗