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At least 109 records · Page 6

The J-2X Upper Stage Engine: From Design to Hardware

NASA is well on its way toward developing a new generation of launch vehicles to support of national space policy to retire the Space Shuttle fleet, complete the International Space Station, and return to the Moon as the first step in resuming this nation s exploration of deep space. The Constellation Program is developing the launch vehicles, spacecraft, surface systems, and ground systems to support those plans. Two launch vehicles will support those ambitious plans the Ares I and Ares V. (Figure 1) The J-2X Upper Stage Engine is a critical element of both of these new launchers. This paper will provide an overview of the J-2X design background, progress to date in design, testing, and manufacturing. The Ares I crew launch vehicle will lift the Orion crew exploration vehicle and up to four astronauts into low Earth orbit (LEO) to rendezvous with the space station or the first leg of mission to the Moon. The Ares V cargo launch vehicle is designed to lift a lunar lander into Earth orbit where it will be docked with the Orion spacecraft, and provide the thrust for the trans-lunar journey. While these vehicles bear some visual resemblance to the 1960s-era Saturn vehicles that carried astronauts to the Moon, the Ares vehicles are designed to carry more crew and more cargo to more places to carry out more ambitious tasks than the vehicles they succeed. The government/industry team designing the Ares rockets is mining a rich history of technology and expertise from the Shuttle, Saturn and other programs and seeking commonality where feasible between the Ares crew and cargo rockets as a way to minimize risk, shorten development times, and live within the budget constraints of its original guidance.

Byrd, Thomas↗

The Boeing 747 fatigue integrity program

The fatigue integrity program which was established to insure economic operations and to provide foundation data for inspection and maintenance is discussed. Significant features of the 747 fatigue integrity program are: (1) fatigue analyses which are continually updated to reflect design changes, fatigue test results, and static and flight load survey measurements; (2) material selection and detail design by using initial fatigue analyses, service experience, and testing; and (3) fatigue testing to check detail design quality and to verify the analyses, culminated by the test of a structurally complete airframe. Fatigue stress analyses were performed with the aid of experimental as well as analytical procedures. Extensive application was made of the stress severity factor, developed at Boeing, for evaluating peak stresses in complex joints. A frame of reference was established by families of structural fatigue performance curves (S-N curves) encompassing the range of materials and fatigue qualities anticipated for the 747 airplane design.

Spencer, M. M.↗

Mission analysis data for inclined geosynchronous orbits, part 1

Data needed for preliminary design of inclined geosynchronous missions are provided. The inertial and Earth fixed coordinate systems are described, as well as orbit parameters and elements. The complete family of geosynchronous orbits is discussed. It is shown that circular inclined geosynchronous orbits comprise only one set in this family. The major orbit perturbation and their separate effects on the geosynchronous orbit are discussed. Detailed information on the orbit perturbation of inclined circular geosynchronous orbits is given, with emphasis on time history data of certain orbital elements. Orbit maintenance delta velocity (V) requirements to counteract the major orbit perturbations are determined in order to provide order of magnitude estimates and to show the effects of orbit inclination on delta V. Some of the considerations in mission design for a multisatellite system, such as a halo orbit constellation, are discussed.

Graf, O. F., Jr.↗

Computational Fluid Dynamics (CFD) Design of a Blended Wing Body (BWB) with Boundary Layer Ingestion (BLI) Nacelles

A study is being conducted to improve the propulsion/airframe integration for the Blended Wing-Body (BWB) configuration with boundary layer ingestion nacelles. TWO unstructured grid flow solvers, USM3D and FUN3D, have been coupled with different design methods and are being used to redesign the aft wing region and the nacelles to reduce drag and flow separation. An initial study comparing analyses from these two flow solvers against data from a wind tunnel test as well as predictions from the OVERFLOW structured grid code for a BWB without nacelles has been completed. Results indicate that the unstructured grid codes are sufficiently accurate for use in design. Results from the BWB design study will be presented.

Morehouse, Melissa B.↗

High velocity continuous-flow reactor for the production of solar grade silicon

The feasibility of a high volume, high velocity continuous reduction reactor as an economical means of producing solar grade silicon was tested. Bromosilanes and hydrogen were used as the feedstocks for the reactor along with preheated silicon particles which function both as nucleation and deposition sites. A complete reactor system was designed and fabricated. Initial preheating studies have shown the stability of tetrabromosilane to being heated as well as the ability to preheat hydrogen to the desired temperature range. Several test runs were made and some silicon was obtained from runs carried out at temperatures in excess of 1180 K.

Woerner, L.↗

Mars Smart Lander Parachute Simulation Model

A multi-body flight simulation for the Mars Smart Lander has been developed that includes six degree-of-freedom rigid-body models for both the supersonically-deployed and subsonically-deployed parachutes. This simulation is designed to be incorporated into a larger simulation of the entire entry, descent and landing (EDL) sequence. The complete end-to-end simulation will provide attitude history predictions of all bodies throughout the flight as well as loads on each of the connecting lines. Other issues such as recontact with jettisoned elements (heat shield, back shield, parachute mortar covers, etc.), design of parachute and attachment points, and desirable line properties can also be addressed readily using this simulation.

Queen, Eric M.↗

Markov reward processes

Numerous applications in the area of computer system analysis can be effectively studied with Markov reward models. These models describe the behavior of the system with a continuous-time Markov chain, where a reward rate is associated with each state. In a reliability/availability model, upstates may have reward rate 1 and down states may have reward rate zero associated with them. In a queueing model, the number of jobs of certain type in a given state may be the reward rate attached to that state. In a combined model of performance and reliability, the reward rate of a state may be the computational capacity, or a related performance measure. Expected steady-state reward rate and expected instantaneous reward rate are clearly useful measures of the Markov reward model. More generally, the distribution of accumulated reward or time-averaged reward over a finite time interval may be determined from the solution of the Markov reward model. This information is of great practical significance in situations where the workload can be well characterized (deterministically, or by continuous functions e.g., distributions). The design process in the development of a computer system is an expensive and long term endeavor. For aerospace applications the reliability of the computer system is essential, as is the ability to complete critical workloads in a well defined real time interval. Consequently, effective modeling of such systems must take into account both performance and reliability. This fact motivates our use of Markov reward models to aid in the development and evaluation of fault tolerant computer systems.

Smith, R. M.↗

Verifying Correct Functionality of Avionics Subsystems

This project focuses on the testing of the telecommunications interface subsystem of the Multi-Mission System Architecture Platform to ensure proper functionality. The Multi-Mission System Architecture Platform is a set of basic tools designed to be used in future spacecraft. The responsibilities of the telecommunications interface include communication between the spacecraft and ground teams as well as acting as the bus controller for the system. The tests completed include bit wise read\write tests to each register, testing of status bits, and verifying various bus controller activities. Testing is accomplished through the use of software-based simulations run on an electronic design of the system. The tests are written in Verilog Hardware Definition Language and they simulate specific states and conditions in telecommunication interfaces. Upon successful completion, the output is examined to verify that the system responded appropriately.

Meuer, Ben t.↗

Thinking Inside the Box: A Hands-On Student Activity for Building a Contamination Containment Glovebox to Encourage Problem Solving in a Collaborative Environment

Contamination containment gloveboxes are sealed containers where operators outside the glovebox can safely manipulate hazardous or contamination-sensitive materials inside the glovebox through glove ports on the container. Containment gloveboxes are used in the space industry to study sample materials returned from space such as lunar, asteroid, and comet materials, to manufacture sensitive instruments and space ight hardware, and to perform contamination-sensitive experiments. A hands-on activity has been developed by contamination control engineer and STEM education experts as part of the Virginia Earth System Science Scholars (VESSS) summer academy program to teach high school students about gloveboxes and about problem solving in a collaborative environment. In this activity, student teams are given a list of common household materials (e.g. plastic bags, plastic straws, aluminum foil, tape, disposable gloves, etc.) for building their own glovebox. Students work together to sketch and design their glovebox before being provided a kit of materials, which they must purchase along with any extra materials with a mock team budget. They are given 30 minutes to build their glovebox, however, they do not know what will be placed inside the glovebox or what operations they will need to perform within the glovebox. At the end of the build time, teams are given a small, sealed paper envelope which they place in the glovebox. Each team selects a team member to be designated as the operator, and the operator places their hands in the gloves of the glovebox. The operator uses their gloves to open the envelope in the glovebox, and they discover they have 20 minutes to assemble a jigsaw puzzle. However, the puzzle is \contaminated" with talcum powder. After the 20 minute time period, teams are judged on how well they completed and cleaned the contaminated puzzle. In a post-activity debrief, teams discuss lessons learned such as how the actual built box di ered from the sketched design, the challenge of managing a budget for materials, how the team dealt with surprises, and if their glovebox allowed enough room for the operator to perform the task. This activity has been part of the VESSS summer academy since 2016, and teaches students teamwork, creativity, hands-on experimentation, communication, and reasoning skills. In a demonstration at IAC, a volunteer from the audience will be chosen to assemble a glovebox during the presentation using the same kit of materials and will demonstrate handling puzzle pieces in the completed glovebox.

Elaine Seasly↗

Assessment of Alphamagnetic Spectrometer (AMS) Upper Experiment Structural Configuration Shielding Effectiveness Associated with Change from Cryo-Cooled Magnet to Permanent Magnet

In the spring of 2010, the Alpha Magnetic Spectrometer 2 (AMS-02) underwent a series of system level electromagnetic interference control measurements, followed by thermal vacuum testing. Shortly after completion of the thermal vacuum testing, the project decided to remove the cryogenically cooled superconducting magnet, and replace it with the original permanent magnet design employed in the earlier AMS- 01 assembly. Doing so necessitated several structural changes, as well as removal or modification of numerous electronic and thermal control devices and systems. At this stage, the project was rapidly approaching key milestone dates for hardware completion and delivery for launch, and had little time for additional testing or assessment of any impact to the electromagnetic signature of the AMS-02. Therefore, an analytical assessment of the radiated emissions behavioural changes associated with the system changes was requested.

Scully, Robert↗

A lightweight, high strength dexterous manipulator for commercial applications

The concept, design, and features are described of a lightweight, high strength, modular robot manipulator being developed for space and commercial applications. The manipulator has seven fully active degrees of freedom and is fully operational in 1 G. Each of the seven joints incorporates a unique drivetrain design which provides zero backlash operation, is insensitive to wear, and is single fault tolerant to motor or servo amplifier failure. Feedback sensors provide position, velocity, torque, and motor winding temperature information at each joint. This sensing system is also designed to be single fault tolerant. The manipulator consists of five modules (not including gripper). These modules join via simple quick-disconnect couplings and self-mating connectors which allow rapid assembly and/or disassembly for reconfiguration, transport, or servicing. The manipulator is a completely enclosed assembly, with no exposed components or wires. Although the initial prototype will not be space qualified, the design is well suited to meeting space requirements. The control system provides dexterous motion by controlling the endpoint location and arm pose simultaneously. Potential applications are discussed.

Marzwell, Neville I.↗

Advanced telerobotic control using neural networks

Accurate Automation is designing and developing adaptive decentralized joint controllers using neural networks. We are then implementing these in hardware for the Marshall Space Flight Center PFMA as well as to be usable for the Remote Manipulator System (RMS) robot arm. Our design is being realized in hardware after completion of the software simulation. This is implemented using a Functional-Link neural network.

Pap, Robert M.↗

Compact, low profile antennas for MSAT and mini-M and Std-M land mobile satellite communications

CAL Corporation has developed a new class of low profile radiating elements for use in planar phased array antennas. These new elements have been used in the design of a low cost, compact, low profile antenna unit for MSAT and INMARSAT Mini-M land mobile satellite communications. The antenna unit which measures roughly 32 cm in diameter by 5 cm deep incorporates a compact LNA and diplexer unit as well as a complete, low cost, beam steering system. CAL has also developed a low profile antenna unit for INMARSAT-M land mobile satellite communications. A number of these units, which utilize a microstrip patch array design, were put into service in 1994.

Strickland, P. C.↗

An Autonomous Sensor System Architecture for Active Flow and Noise Control Feedback

Multi-channel sensor fusion represents a powerful technique to simply and efficiently extract information from complex phenomena. While the technique has traditionally been used for military target tracking and situational awareness, a study has been successfully completed that demonstrates that sensor fusion can be applied equally well to aerodynamic applications. A prototype autonomous hardware processor was successfully designed and used to detect in real-time the two-dimensional flow reattachment location generated by a simple separated-flow wind tunnel model. The success of this demonstration illustrates the feasibility of using autonomous sensor processing architectures to enhance flow control feedback signal generation.

Humphreys, William M, Jr.↗

The Application of Lean Thinking Principles and Kaizen Practices for the Successful Development and Implementation of the Ares I-X Flight Test Rocket and Mission

On October 28, 2009 the Ares I-X flight test rocket launched from Kennedy Space Center and flew its suborbital trajectory as designed. The mission was successfully completed as data from the test, and associated development activities were analyzed, transferred to stakeholders, and well documented. Positive lessons learned from Ares I-X were that the application of lean thinking principles and kaizen practices are effective in streamlining development activities. Ares I-X, like other historical rocket development projects, was hampered by technical, cost, and schedule challenges and if not addressed boldly could have resulted in cancellation of the test. The mission management team conducted nine major meetings, referred to as lean events, across its elements to assess plans, procedures, processes, requirements, controls, culture, organization, use of resources, and anything that could be changed to optimize schedule or reduce risk. The preeminent aspect of the lean events was the focus on value added activities and the removal or at least reduction in non-value activities. Trained Lean Six Sigma facilitators assisted the Ares I-X developers in conducting the lean events. They indirectly helped formulate the mission s own unique methodology for assessing schedule. A core team was selected to lead the events and report to the mission manager. Each activity leveraged specialized participants to analyze the subject matter and its related processes and then recommended alternatives and solutions. Stakeholders were the event champions. They empowered and encouraged the team to succeed. The keys to success were thorough preparation, honest dialog, small groups, adherence to the Ares I-X ground rules, and accountability through disciplined reporting and tracking of actions. This lean event formula was game-changing as demonstrated by the success of Ares I-X. It is highly recommended as a management tool to help develop other complex systems efficiently. The key benefits for Ares I-X were obtaining unambiguous schedule margin, defining enabling options for risk reduction, and most importantly a stronger more unified team.

Askins, B. R.↗

The Application of Lean Thinking Principles and Kaizen Practices for the Successful Development and Implementation of the Ares I-X Flight Test Rocket and Mission

On October 28, 2009 the Ares I-X flight test rocket launched from Kennedy Space Center and flew its suborbital trajectory as designed. The mission was successfully completed as data from the test, and associated development activities were analyzed, transferred to stakeholders, and well documented. A positive lesson learned from Ares I-X was that the application of lean thinking principles and kaizen practices was very effective in streamlining development activities. Ares I-X, like other historical rocket development projects, was hampered by technical, cost, and schedule challenges and if not addressed boldly could have resulted in cancellation of the test. The mission management team conducted nine major meetings, referred to as lean events, across its elements to assess plans, procedures, processes, requirements, controls, culture, organization, use of resources, and anything that could be changed to optimize schedule or reduce risk. The preeminent aspect of the lean events was the focus on value added activities and the removal or at least reduction in non-value added activities. Trained Lean Six Sigma facilitators assisted the Ares I-X developers in conducting the lean events. They indirectly helped formulate the mission s own unique methodology for assessing schedule. A core team was selected to lead the events and report to the mission manager. Each activity leveraged specialized participants to analyze the subject matter and its related processes and then recommended alternatives and solutions. Stakeholders were the event champions. They empowered and encouraged the team to succeed. The keys to success were thorough preparation, honest dialog, small groups, adherence to the Ares I-X ground rules, and accountability through disciplined reporting and tracking of actions. This lean event formula was game-changing as demonstrated by Ares I-X. It is highly recommended as a management tool to help develop other complex systems efficiently. The key benefits for Ares I-X were obtaining unambiguous schedule margin, defining enabling options for risk reduction, and most importantly a stronger more unified team.

Askins, B. R.↗

Chirped-Superlattice, Blocked-Intersubband QWIP

An Al(x)Ga(1-x)As/GaAs quantum-well infrared photodetector (QWIP) of the blocked-intersubband-detector (BID) type, now undergoing development, features a chirped (that is, aperiodic) superlattice. The purpose of the chirped superlattice is to increase the quantum efficiency of the device. A somewhat lengthy background discussion is necessary to give meaning to a brief description of the present developmental QWIP. A BID QWIP was described in "MQW Based Block Intersubband Detector for Low-Background Operation" (NPO-21073), NASA Tech Briefs Vol. 25, No. 7 (July 2001), page 46. To recapitulate: The BID design was conceived in response to the deleterious effects of operation of a QWIP at low temperature under low background radiation. These effects can be summarized as a buildup of space charge and an associated high impedance and diminution of responsivity with increasing modulation frequency. The BID design, which reduces these deleterious effects, calls for a heavily doped multiple-quantum-well (MQW) emitter section with barriers that are thinner than in prior MQW devices. The thinning of the barriers results in a large overlap of sublevel wave functions, thereby creating a miniband. Because of sequential resonant quantum-mechanical tunneling of electrons from the negative ohmic contact to and between wells, any space charge is quickly neutralized. At the same time, what would otherwise be a large component of dark current attributable to tunneling current through the whole device is suppressed by placing a relatively thick, undoped, impurity-free AlxGa1 x As blocking barrier layer between the MQW emitter section and the positive ohmic contact. [This layer is similar to the thick, undoped Al(x)Ga(1-x)As layers used in photodetectors of the blocked-impurity-band (BIB) type.] Notwithstanding the aforementioned advantage afforded by the BID design, the responsivity of a BID QWIP is very low because of low collection efficiency, which, in turn, is a result of low electrostatic- potential drop across the superlattice emitter. Because the emitter must be electrically conductive to prevent the buildup of space charge in depleted quantum wells, most of the externally applied bias voltage drop occurs across the blocking-barrier layer. This completes the background discussion. In the developmental QWIP, the periodic superlattice of the prior BID design is to be replaced with the chirped superlattice, which is expected to provide a built-in electric field. As a result, the efficiency of collection of photoexcited charge carriers (and, hence, the net quantum efficiency and thus responsivity) should increase significantly.

Gunapala, Sarath↗

Designing for Change: Minimizing the Impact of Changing Requirements in the Later Stages of a Spaceflight Software Project

In the traditional 'waterfall' model of the software project life cycle, the Requirements Phase ends and flows into the Design Phase, which ends and flows into the Development Phase. Unfortunately, the process rarely, if ever, works so smoothly in practice. Instead, software developers often receive new requirements, or modifications to the original requirements, well after the earlier project phases have been completed. In particular, projects with shorter than ideal schedules are highly susceptible to frequent requirements changes, as the software requirements analysis phase is often forced to begin before the overall system requirements and top-level design are complete. This results in later modifications to the software requirements, even though the software design and development phases may be complete. Requirements changes received in the later stages of a software project inevitably lead to modification of existing developed software. Presented here is a series of software design techniques that can greatly reduce the impact of last-minute requirements changes. These techniques were successfully used to add built-in flexibility to two complex software systems in which the requirements were expected to (and did) change frequently. These large, real-time systems were developed at NASA Langley Research Center (LaRC) to test and control the Lidar In-Space Technology Experiment (LITE) instrument which flew aboard the space shuttle Discovery as the primary payload on the STS-64 mission.

Allen, B. Danette↗