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NASA NTRS2011

Lessons Learned in Engineering

This Contractor Report (CR) is a compilation of Lessons Learned in approximately 55 years of engineering experience by each James C. Blair, Robert S. Ryan, and Luke A. Schutzenhofer. The lessons are the basis of a course on Lessons Learned that has been taught at Marshall Space Flight Center. The lessons are drawn from NASA space projects and are characterized in terms of generic lessons learned from the project experience, which are further distilled into overarching principles that can be applied to future projects. Included are discussions of the overarching principles followed by a listing of the lessons associated with that principle. The lesson with sub-lessons are stated along with a listing of the project problems the lesson is drawn from, then each problem is illustrated and discussed, with conclusions drawn in terms of Lessons Learned. The purpose of this CR is to provide principles learned from past aerospace experience to help achieve greater success in future programs, and identify application of these principles to space systems design. The problems experienced provide insight into the engineering process and are examples of the subtleties one experiences performing engineering design, manufacturing, and operations.

Blair, J. C.↗

NASA NTRS2011

Lessons Learned in Engineering

Blair, James C.↗

NASA NTRS2011

MicroShell Minimalist Shell for Xilinx Microprocessors

MicroShell is a lightweight shell environment for engineers and software developers working with embedded microprocessors in Xilinx FPGAs. (MicroShell has also been successfully ported to run on ARM Cortex-M1 microprocessors in Actel ProASIC3 FPGAs, but without project-integration support.) Micro Shell decreases the time spent performing initial tests of field-programmable gate array (FPGA) designs, simplifies running customizable one-time-only experiments, and provides a familiar-feeling command-line interface. The program comes with a collection of useful functions and enables the designer to add an unlimited number of custom commands, which are callable from the command-line. The commands are parameterizable (using the C-based command-line parameter idiom), so the designer can use one function to exercise hardware with different values. Also, since many hardware peripherals instantiated in FPGAs have reasonably simple register-mapped I/O interfaces, the engineer can edit and view hardware parameter settings at any time without stopping the processor. MicroShell comes with a set of support scripts that interface seamlessly with Xilinx's EDK tool. Adding an instance of MicroShell to a project is as simple as marking a check box in a library configuration dialog box and specifying a software project directory. The support scripts then examine the hardware design, build design-specific functions, conditionally include processor-specific functions, and complete the compilation process. For code-size constrained designs, most of the stock functionality can be excluded from the compiled library. When all of the configurable options are removed from the binary, MicroShell has an unoptimized memory footprint of about 4.8 kB and a size-optimized footprint of about 2.3 kB. Since MicroShell allows unfettered access to all processor-accessible memory locations, it is possible to perform live patching on a running system. This can be useful, for instance, if a bug is discovered in a routine but the system cannot be rebooted: Shell allows a skilled operator to directly edit the binary executable in memory. With some forethought, MicroShell code can be located in a different memory location from custom code, permitting the custom functionality to be overwritten at any time without stopping the controlling shell.

Werne, Thomas A.↗

NASA NTRS1993

Ten years in the library: new data confirm paleontological patterns

A comparison is made between compilations of times of origination and extinction of fossil marine animal families published in 1982 and 1992. As a result of ten years of library research, half of the information in the compendia has changed: families have been added and deleted, low-resolution stratigraphic data been improved, and intervals of origination and extinction have been altered. Despite these changes, apparent macroevolutionary patterns for the entire marine fauna have remained constant. Diversity curves compiled from the two data bases are very similar, with a goodness-of-fit of 99%; the principal difference is that the 1992 curve averages 13% higher than the older curve. Both numbers and percentages of origination and extinction also match well, with fits ranging from 83% to 95%. All major events of radiation and extinction are identical. Therefore, errors in large paleontological data bases and arbitrariness of included taxa are not necessarily impediments to the analysis of pattern in the fossil record, so long as the data are sufficiently numerous.

NASA Discipline Number 52-40↗

NASA NTRS1997

"TPSX: Thermal Protection System Expert and Material Property Database"

The Thermal Protection Branch at NASA Ames Research Center has developed a computer program for storing, organizing, and accessing information about thermal protection materials. The program, called Thermal Protection Systems Expert and Material Property Database, or TPSX, is available for the Microsoft Windows operating system. An "on-line" version is also accessible on the World Wide Web. TPSX is designed to be a high-quality source for TPS material properties presented in a convenient, easily accessible form for use by engineers and researchers in the field of high-speed vehicle design. Data can be displayed and printed in several formats. An information window displays a brief description of the material with properties at standard pressure and temperature. A spread sheet window displays complete, detailed property information. Properties which are a function of temperature and/or pressure can be displayed as graphs. In any display the data can be converted from English to SI units with the click of a button. Two material databases included with TPSX are: 1) materials used and/or developed by the Thermal Protection Branch at NASA Ames Research Center, and 2) a database compiled by NASA Johnson Space Center 9JSC). The Ames database contains over 60 advanced TPS materials including flexible blankets, rigid ceramic tiles, and ultra-high temperature ceramics. The JSC database contains over 130 insulative and structural materials. The Ames database is periodically updated and expanded as required to include newly developed materials and material property refinements.

Squire, Thomas H.↗

NASA NTRS2022

Orbital Trade Study for the PREFIRE Mission

The Polar Radiant Energy in the Far-Infrared Experiment (PREFIRE) is a low-cost cubesat-based Earth Science mission selected for rapid implementation through NASAs Earth Ventures-Instrument program. Two cubesats carrying thermal infrared spectrometers (TIRS) in polar orbits will test long-held assumptions regarding radiative balance at long wavelengths where the cold-dry Arctic and Antarctic surfaces expel significant amounts of the earth's radiant energy. Thermal radiometry with better than one micron sampling at wavelengths beyond 15 microns will provide critical observational bounds for inputs into glacier melt and climate change models through improvements in surface emissivities, longwave greenhouse effect parameterizations, and cloud presence/types. Additional information on potential far-infrared surface/atmosphere feedbacks during rapid melt processes may be captured with sub-diurnal revisits of targeted areas. A baseline mission with two cubesats in different orbits provides a means for optimization of sub-diurnal sampling for science purposes. In this presentation we provide details of orbit studies that inform expected sampling metrics. Candidate orbits are modeled in SGP and then TIRS sampling is projected into surface footprints with appropriate geo-location. Matching algorithms then compile statistics for time-delayed revisits between and within the two orbits. Binning of results by latitude allows for abstraction of precession issues as well as for correlations with surface types as defined by radiometric classification schemes. Multiple acceptable pairs of science-driven orbits were found that optimize sampling in areas known to experience rapid melt events. The final choice of PREFIRE orbital parameters includes the systems trade-space, particularly the power budget, as well as the availability of launch opportunities.

"L'Ecuyer, Tristan"↗

NASA NTRS1996

1996 Coolant Flow Management Workshop

The following compilation of documents includes a list of the 66 attendees, a copy of the viewgraphs presented, and a summary of the discussions held after each session at the 1996 Coolant Flow Management Workshop held at the Ohio Aerospace Institute, adjacent to the NASA Lewis Research Center, Cleveland, Ohio on December 12-13, 1996. The workshop was organized by H. Joseph Gladden and Steven A. Hippensteele of NASA Lewis Research Center. Participants in this workshop included Coolant Flow Management team members from NASA Lewis, their support service contractors, the turbine engine companies, and the universities. The participants were involved with research projects, contracts and grants relating to: (1) details of turbine internal passages, (2) computational film cooling capabilities, and (3) the effects of heat transfer on both sides. The purpose of the workshop was to assemble the team members, along with others who work in gas turbine cooling research, to discuss needed research and recommend approaches that can be incorporated into the Center's Coolant Flow Management program. The workshop was divided into three sessions: (1) Internal Coolant Passage Presentations, (2) Film Cooling Presentations, and (3) Coolant Flow Integration and Optimization. Following each session there was a group discussion period.

Steven A. Hippensteele↗

NASA NTRS1994

Spacecraft On-Board Information Extraction Computer (SOBIEC)

The Jet Propulsion Laboratory is the Technical Monitor on an SBIR Program issued for Irvine Sensors Corporation to develop a highly compact, dual use massively parallel processing node known as SOBIEC. SOBIEC couples 3D memory stacking technology provided by nCUBE. The node contains sufficient network Input/Output to implement up to an order-13 binary hypercube. The benefit of this network, is that it scales linearly as more processors are added, and it is a superset of other commonly used interconnect topologies such as: meshes, rings, toroids, and trees. In this manner, a distributed processing network can be easily devised and supported. The SOBIEC node has sufficient memory for most multi-computer applications, and also supports external memory expansion and DMA interfaces. The SOBIEC node is supported by a mature set of software development tools from nCUBE. The nCUBE operating system (OS) provides configuration and operational support for up to 8000 SOBIEC processors in an order-13 binary hypercube or any subset or partition(s) thereof. The OS is UNIX (USL SVR4) compatible, with C, C++, and FORTRAN compilers readily available. A stand-alone development system is also available to support SOBIEC test and integration.

Eisenman, David↗

NASA NTRS2003

Columbia Accident Investigation Board Report. Volume Six

In the course of its inquiry into the February 1, 2003 destruction of the Space Shuttle Columbia, the Columbia Accident Investigation Board conducted a series of public hearings at Houston, Texas; Cape Canaveral, Florida; and Washington, DC. Testimony from these hearings was recorded and then transcribed. This appendix, Volume VI of the Report, is a compilation of those transcripts. Contents: Transcripts of Board Public Hearings; Appendix H.1 March 6, 2003 Houston, Texas; Appendix H.2 March 17, 2003 Houston, Texas; Appendix H.3 March 18, 2003 Houston, Texas; Appendix H. 4 March 25, 2003 Cape Canaveral, Florida; Appendix H.5 March 26, 2003 Cape Canaveral, Florida; Appendix H.6 April 7, 2003 Houston, Texas; Appendix H.7 April 8, 2003 Houston, Texas; Appendix H.8 April 23, 2003 Houston, Texas; Appendix H.9 May 6, 2003 Houston, Texas; Appendix H.10 June 12, 2003 Washington, DC.

CAIB (COLUMBIA ACCIDENT INVESTIGATION BOARD)↗

NASA NTRS1993

Insect diversity in the fossil record

Insects possess a surprisingly extensive fossil record. Compilation of the geochronologic ranges of insect families demonstrates that their diversity exceeds that of preserved vertebrate tetrapods through 91 percent of their evolutionary history. The great diversity of insects was achieved not by high origination rates but rather by low extinction rates comparable to the low rates of slowly evolving marine invertebrate groups. The great radiation of modern insects began 245 million years ago and was not accelerated by the expansion of angiosperms during the Cretaceous period. The basic trophic machinery of insects was in place nearly 100 million years before angiosperms appeared in the fossil record.

NASA Discipline Exobiology↗

NASA NTRS2013

Design and Development of Functionally Effective Human-Machine Interfaces for Firing Room Displays

This project involves creating software for support equipment used on the Space l aunch System (SLS). The goal is to create applications and displays that will be used to remotely operate equipment from the firing room and will continue to support the SLS launch vehicle to the extent of its program. These displays include design practices that help to convey information effectively, such as minimizing distractions at normal operating state and displaying intentional distractions during a warning or alarm state. The general practice for creating an operator display is to reduce the detail of unimportant aspects of the display and promote focus on data and dynamic information. These practices include using minimalist design, using muted tones for background colors, using a standard font at a readable text size, displaying alarms visible for Immediate attention, grouping data logically, and displaying data appropriately varying on the type of data. Users of these displays are more likely to stay focused on operating for longer periods by using design practices that reduce eye strain and fatigue. Effective operator displays will improve safety by reducing human errors during operation, which will help prevent catastrophic accidents. This report entails the details of my work on developing remote displays for the Hypergolics ground system. Before developing a prototype display, the design and requirements of the system are outlined and compiled into a document. Then each subsystem has schematic representations drawn tha.t meet the specifications detailed in the document. The schematics are then used as the outline to create display representations of each subsystem. Each display is first tested individually. Then the displays are integrated with a prototype of the master system, and they are tested in a simulated environment then retested in the real environment. Extensive testing is important to ensure the displays function reliably as intended.

Cho, Henry↗

NASA NTRS2008

MISR Instrument Data Visualization

The MISR Interactive eXplorer (MINX) software functions both as a general-purpose tool to visualize Multiangle Imaging SpectroRadiometer (MISR) instrument data, and as a specialized tool to analyze properties of smoke, dust, and volcanic plumes. It includes high-level options to create map views of MISR orbit locations; scrollable, single-camera RGB (red-greenblue) images of MISR level 1B2 (L1B2) radiance data; and animations of the nine MISR camera images that provide a 3D perspective of the scenes that MISR has acquired. NASA Tech Briefs, September 2008 55 The plume height capability provides an accurate estimate of the injection height of plumes that is needed by air quality and climate modelers. MISR provides global high-quality stereo height information, and this program uses that information to perform detailed height retrievals of aerosol plumes. Users can interactively digitize smoke, dust, or volcanic plumes and automatically retrieve heights and winds, and can also archive MISR albedos and aerosol properties, as well as fire power and brightness temperatures associated with smoke plumes derived from Moderate Resolution Imaging Spectroradiometer (MODIS) data. Some of the specialized options in MINX enable the user to do other tasks. Users can display plots of top-of-atmosphere bidirectional reflectance factors (BRFs) versus camera-angle for selected pixels. Images and animations can be saved to disk in various formats. Also, users can apply a geometric registration correction to warp camera images when the standard processing correction is inadequate. It is possible to difference the images of two MISR orbits that share a path (identical ground track), as well as to construct pseudo-color images by assigning different combinations of MISR channels (angle or spectral band) to the RGB display channels. This software is an interactive application written in IDL and compiled into an IDL Virtual Machine (VM) ".sav" file.

Nelson, David↗

NASA NTRS2013

Design and Development of Functionally Effective Human-Machine Interfaces for Firing Room Displays

This project involves creating software for support equipment used on the Space Launch System (SLS). The goal is to create applications and displays that will be used to remotely operate equipment from the firing room and will continue to support the SLS launch vehicle to the extent of its program. These displays include design practices that help to convey information effectively, such as minimizing distractions at normal operating state and displaying intentional distractions during a warning or alarm state. The general practice for creating an operator display is to reduce the detail of unimportant aspects of the display and promote focus on data and dynamic information. These practices include using minimalist design, using muted tones for background colors, using a standard font at a readable text size, displaying alarms visible for immediate attention, grouping data logically, and displaying data appropriately varying on the type of data. Users of these displays are more likely to stay focused on operating for longer periods by using design practices that reduce eye strain and fatigue. Effective operator displays will improve safety by reducing human errors during operation, which will help prevent catastrophic accidents. This report entails the details of my work on developing remote displays for the Hypergolic fuel servicing system. Before developing a prototype display, the design and requirements of the system are outlined and compiled into a document. Then each subsystem has schematic representations drawn that meet the specifications detailed in the document. The schematics are then used as the outline to create display representations of each subsystem. Each display is first tested individually. Then the displays are integrated with a prototype of the master system, and they are tested in a simulated environment then retested in the real environment. Extensive testing is important to ensure the displays function reliably as intended.

displays↗

NASA NTRS2016

An Integrated Extravehicular Activity Research Plan

Multiple organizations within NASA and outside of NASA fund and participate in research related to extravehicular activity (EVA). In October 2015, representatives of the EVA Office, the Crew and Thermal Systems Division (CTSD), and the Human Research Program (HRP) at NASA Johnson Space Center agreed on a formal framework to improve multi-year coordination and collaboration in EVA research. At the core of the framework is an Integrated EVA Research Plan and a process by which it will be annually reviewed and updated. The over-arching objective of the collaborative framework is to conduct multi-disciplinary cost-effective research that will enable humans to perform EVAs safely, effectively, comfortably, and efficiently, as needed to enable and enhance human space exploration missions. Research activities must be defined, prioritized, planned and executed to comprehensively address the right questions, avoid duplication, leverage other complementary activities where possible, and ultimately provide actionable evidence-based results in time to inform subsequent tests, developments and/or research activities. Representation of all appropriate stakeholders in the definition, prioritization, planning and execution of research activities is essential to accomplishing the over-arching objective. A formal review of the Integrated EVA Research Plan will be conducted annually. External peer review of all HRP EVA research activities including compilation and review of published literature in the EVA Evidence Book is already performed annually. Coordination with stakeholders outside of the EVA Office, CTSD, and HRP is already in effect on a study-by-study basis; closer coordination on multi-year planning with other EVA stakeholders including academia is being actively pursued. Details of the current Integrated EVA Research Plan are presented including description of ongoing and planned research activities in the areas of: Benchmarking; Anthropometry and Suit Fit; Sensors; Human-Suit Modeling; Suit Trauma Monitoring and Countermeasures; EVA Workload and Duration Effects; Decompression Sickness Risk Mitigation; Deconditioned EVA Performance; and Exploration EVA Concept of Operations.

Abercromby, Andrew F. J.↗

NASA NTRS2004

Architecture and Functionality of the Advanced Life Support On-Line Project Information System (OPIS)

An ongoing effort is underway at NASA Amcs Research Center (ARC) tu develop an On-line Project Information System (OPIS) for the Advanced Life Support (ALS) Program. The objective of this three-year project is to develop, test, revise and deploy OPIS to enhance the quality of decision-making metrics and attainment of Program goals through improved knowledge sharing. OPIS will centrally locate detailed project information solicited from investigators on an annual basis and make it readily accessible by the ALS Community via a web-accessible interface. The data will be stored in an object-oriented relational database (created in MySQL(Trademark) located on a secure server at NASA ARC. OPE will simultaneously serve several functions, including being an R&TD status information hub that can potentially serve as the primary annual reporting mechanism. Using OPIS, ALS managers and element leads will be able to carry out informed research and technology development investment decisions, and allow analysts to perform accurate systems evaluations. Additionally, the range and specificity of information solicited will serve to educate technology developers of programmatic needs. OPIS will collect comprehensive information from all ALS projects as well as highly detailed information specific to technology development in each ALS area (Waste, Water, Air, Biomass, Food, Thermal, and Control). Because the scope of needed information can vary dramatically between areas, element-specific technology information is being compiled with the aid of multiple specialized working groups. This paper presents the current development status in terms of the architecture and functionality of OPIS. Possible implementation approaches for OPIS are also discussed.

Hogan, John A.↗

NASA NTRS2004

Changes in Hardware in Order to Accommodate Compliant Foil Air Bearings of a Larger Size

Compliant foil air bearings are at the forefront of the Oil-Free turbomachinery revolution of supporting gas turbine engines with air lubricated hydrodynamic bearings. Foil air bearings have existed for almost fifty years, yet their commercialization has been confined to relatively small, high-speed systems characterized by low temperatures and loads, such as in air cycle machines, turbocompressors and micro-turbines. Recent breakthroughs in foil air bearing design and solid lubricant coating technology, have caused a resurgence of research towards applying Oil-Free technology to more demanding applications on the scale of small and mid range aircraft gas turbine engines. In order to foster the transition of Oil-Free technology into gas turbine engines, in-house experiments need to be performed on foil air bearings to further the understanding of their complex operating principles. During my internship at NASA Glenn in the summer of 2003, a series of tests were performed to determine the internal temperature profile in a compliant bump- type foil journal air bearing operating at room temperature under various speeds and load conditions. From these tests, a temperature profile was compiled, indicating that the circumferential thermal gradients were negligible. The tests further indicated that both journal rotational speed and radial load are responsible for heat generation with speed playing a more significant role in the magnitude of the temperatures. As a result of the findings from the tests done during the summer of 2003, it was decided that further testing would need to be done, but with a bearing of a larger diameter. The bearing diameter would now be increased from two inches to three inches. All of the currently used testing apparatus was designed specifically for a bearing that was two inches in diameter. Thus, my project for the summer of 2004 was to focus specifically on the scatter shield put around the testing rig while running the bearings. Essentially I was to design a scatter shield that would be able to accommodate the three inch bearing and that would also meet all safety requirements. Furthermore, the new scatter shield also had to house a heater, used for high-speed and temperature testing. Using Solidworks, a computer aided modeling program, I was able to accomplish the task set out for me and designed the new scatter shield. Furthermore, I also guided the fabrication process. As a result of this containment shield being designed, the Oil-Free turbomachinery team now has the ability to test bearings of larger diameters. Finally, it is expected that these tests will provide information useful for the validation of future analytical modeling codes.

Zeszotek, Michelle↗

NASA NTRS2004

Reconfigurable Transceiver and Software-Defined Radio Architecture and Technology Evaluated for NASA Space Communications

The NASA Glenn Research Center is investigating the development and suitability of a software-based open-architecture for space-based reconfigurable transceivers (RTs) and software-defined radios (SDRs). The main objectives of this project are to enable advanced operations and reduce mission costs. SDRs are becoming more common because of the capabilities of reconfigurable digital signal processing technologies such as field programmable gate arrays and digital signal processors, which place radio functions in firmware and software that were traditionally performed with analog hardware components. Features of interest of this communications architecture include nonproprietary open standards and application programming interfaces to enable software reuse and portability, independent hardware and software development, and hardware and software functional separation. The goals for RT and SDR technologies for NASA space missions include prelaunch and on-orbit frequency and waveform reconfigurability and programmability, high data rate capability, and overall communications and processing flexibility. These operational advances over current state-of-art transceivers will be provided to reduce the power, mass, and cost of RTs and SDRs for space communications. The open architecture for NASA communications will support existing (legacy) communications needs and capabilities while providing a path to more capable, advanced waveform development and mission concepts (e.g., ad hoc constellations with self-healing networks and high-rate science data return). A study was completed to assess the state of the art in RT architectures, implementations, and technologies. In-house researchers conducted literature searches and analysis, interviewed Government and industry contacts, and solicited information and white papers from industry on space-qualifiable RTs and SDRs and their associated technologies for space-based NASA applications. The white papers were evaluated, compiled, and used to assess RT and SDR system architectures and core technology elements to determine an appropriate investment strategy to advance these technologies to meet future mission needs. The use of these radios in the space environment represents a challenge because of the space radiation suitability of the components, which drastically reduces the processing capability. The radios available for space are considered to be RTs (as opposed to SDRs), which are digitally programmable radios with selectable changes from an architecture combining analog and digital components. The limited flexibility of this design contrasts against the desire to have a power-efficient solution and open architecture.

Reinhart, Richard C.↗

NASA NTRSDate not supplied

Logistics Rates and Assumptions for Future Human Spaceflight Missions Beyond LEO

As NASA prepares for future human spaceflight missions with extended crew duration in destinations beyond low Earth orbit (LEO), the Agency has focused itself on understanding the drivers to sustainably support human life beyond Earth’s atmosphere. Future missions to deep space, the lunar surface, and eventually the Martian surface pose new challenges in ensuring the crew is sufficiently supplied with all necessary materials. To mitigate the risk of not delivering sufficient consumables and logistics for human spaceflight missions, NASA has examined past human space mission data and developed metabolic modeling to determine estimates for the crew consumption rates of fluids, solid consumables, and additional equipment needed. This paper is a compilation of guidelines, rates, and assumptions necessary to evaluate the logistics needs for future human exploration conceptual missions beyond LEO, providing a starting point and resource of information regarding usage rates and overall logistics supply planning for crewed exploration missions. Logistics represent all equipment and supplies not installed as part of the vehicle that are needed to support mission activities. Logistics can be further divided into specific categories, including consumables, maintenance items, spares, utilization, outfitting, as well as any packaging required. This paper will also provide use case examples of logistics needs to support human missions in deep space, including a conceptual lunar surface mission. The paper provides information necessary to calculate the mass and volume of known logistics for conceptual future human exploration missions beyond LEO. The assumptions in the paper are updated versions of previous assumptions made by the Agency and were derived from a number of sources, including International Space Station (ISS) historical usage and resupply rates, the Life Support Baseline Values and Assumptions Document (BVAD) 2022, Human Integration Design Handbook (HIDH) 2014, and data gathered from NASA human spaceflight programs and projects. The primary goal of the paper is to establish a set of consistent reference rates that multiple teams and groups can utilize to conduct logistics analysis and compare cases. This methodology is for initial estimates of conceptual human missions and does not take the place of detailed analysis for programs, nor does it provide requirements for programs.

Human Spaceflight↗