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NASA NTRS2003

Mercury Conditions for the MESSENGER Mission Simulated in High- Solar-Radiation Vacuum Tests

The MESSENGER (Mercury Surface, Space Environment, Geochemistry, and Ranging) spacecraft, planned for launch in March 2004, will perform two flybys of Mercury before entering a year-long orbit of the planet in September 2009. The mission will provide opportunities for detailed characterization of the surface, interior, atmosphere, and magnetosphere of the closest planet to the Sun. The NASA Glenn Research Center and the MESSENGER spacecraft integrator, the Johns Hopkins University Applied Physics Laboratory, have partnered under a Space Act Agreement to characterize a variety of critical components and materials under simulated conditions expected near Mercury. Glenn's Vacuum Facility 6, which is equipped with a solar simulator, can simulate the vacuum and high solar radiation anticipated in Mercury orbit. The MESSENGER test hardware includes a variety of materials and components that are being characterized during the Tank 6 vacuum tests, where the hardware will be exposed to up to 11 suns insolation, simulating conditions expected in Mercury orbit. In 2002, ten solar vacuum tests were conducted, including beginning of life, end of life, backside exposure, and solar panel thermal shock cycling tests. Components tested include candidate solar array panels, sensors, thermal shielding materials, and communication devices. As an example, for the solar panel thermal shock cycling test, two candidate solar array panels were suspended on a lift mechanism that lowered the panels into a liquid-nitrogen-cooled box. After reaching -140 C, the panels were then lifted out of the box and exposed to the equivalent of 6 suns (8.1 kilowatts per square meters). After five cold soak/heating cycles were completed successfully, there was no apparent degradation in panel performance. An anticipated 100-hr thermal shield life test is planned for autumn, followed by solar panel flight qualification tests in winter. Glenn's ongoing support to the MESSENGER program has been instrumental in identifying design solutions and validating thermal performance models under a very aggressive development schedule. The test data have assisted Johns Hopkins engineers in selecting a flight solar array vendor and a thermal shield design. MESSENGER is one in a series of missions in NASA's Discovery Program. Infrared thermography provides data on the thermal gradients in the MESSENGER components during high solar insolation vacuum testing.

Wong, Wayne A.↗

NASA NTRS2018

Developing Controlled Conductive Boundaries for JWST Cryogenic Testing

In 2017, the James Webb Space Telescope (JWST) underwent functional testing and optical metrology verification of the combined Optical Telescope Element and Integrated Science Instrument Module (OTIS) under cryogenic vacuum conditions in Chamber A at the Johnson Space Center. Maintaining flight-like thermal boundary conditions was a critical requirement for optical testing and required unique and challenging Ground Support Equipment (GSE) design solutions. Two such GSE systems, the Integrated Science Instrument Module (ISIM) Precool Straps and the Hardpoint Struts were direct conduction interfaces to the flight hardware. Hardware safety during cooldown required detailed design of their conductivity, and thermal balance testing required "zero-Q" (0-Q) heater implementation to bring the heat flow to zero, thereby cutting off these non-flight conductive links after operating temperatures were achieved. This paper describes the design considerations and approach implemented to achieve the required flight hardware cool down and return to ambient conditions, ensure flight hardware safety, and minimize the non-flight-like heat flows to or from the observatory during cryo-stable testing.

Cooke, D.↗

NASA NTRS2018

Developing Controlled Conductive Boundaries for JWST Cryogenic Testing

In 2017, the James Webb Space Telescope (JWST) underwent functional testing and optical metrology verification of the combined Optical Telescope Element and Integrated Science Instrument Module (OTIS) under cryogenic vacuum conditions in Chamber A at the Johnson Space Center. Maintaining flight-like thermal boundary conditions was a critical requirement for optical testing and required unique and challenging Ground Support Equipment (GSE) design solutions. Two such GSE systems, the Integrated Science Instrument Module (ISIM) Precool Straps and the Hardpoint Struts were direct conduction interfaces to the flight hardware. Hardware safety during cooldown required detailed design of their conductivity, and thermal balance testing required zero-Q (0-Q) heater implementation to bring the heat flow to zero, thereby cutting off these non-flight conductive links after operating temperatures were achieved. This paper describes the design considerations and approach implemented to achieve the required flight hardware cool down and return to ambient conditions, ensure flight hardware safety, and minimize the non-flight-like heat flows to or from the observatory during cryo-stable testing.

Cooke, Dwight A.↗

NASA NTRS2006

Generative Representations for Computer-Automated Evolutionary Design

With the increasing computational power of computers, software design systems are progressing from being tools for architects and designers to express their ideas to tools capable of creating designs under human guidance. One of the main limitations for these computer-automated design systems is the representation with which they encode designs. If the representation cannot encode a certain design, then the design system cannot produce it. To be able to produce new types of designs, and not just optimize pre-defined parameterizations, evolutionary design systems must use generative representations. Generative representations are assembly procedures, or algorithms, for constructing a design thereby allowing for truly novel design solutions to be encoded. In addition, by enabling modularity, regularity and hierarchy, the level of sophistication that can be evolved is increased. We demonstrate the advantages of generative representations on two different design domains: the evolution of spacecraft antennas and the evolution of 3D objects.

Hornby, Gregory S.↗

NASA NTRS1985

SUBOPT: A CAD program for suboptimal linear regulators

An interactive software package which provides design solutions for both standard linear quadratic regulator (LQR) and suboptimal linear regulator problems is described. Intended for time-invariant continuous systems, the package is easily modified to include sampled-data systems. LQR designs are obtained by established techniques while the large class of suboptimal problems containing controller and/or performance index options is solved using a robust gradient minimization technique. Numerical examples demonstrate features of the package and recent developments are described.

Fleming, P. J.↗

NASA NTRS2011

Electro-Mechanical Systems for Extreme Space Environments

Exploration beyond low earth orbit presents challenges for hardware that must operate in extreme environments. The current state of the art is to isolate and provide heating for sensitive hardware in order to survive. However, this protection results in penalties of weight and power for the spacecraft. This is particularly true for electro-mechanical based technology such as electronics, actuators and sensors. Especially when considering distributed electronics, many electro-mechanical systems need to be located in appendage type locations, making it much harder to protect from the extreme environments. The purpose of this paper to describe the advances made in the area of developing electro-mechanical technology to survive these environments with minimal protection. The Jet Propulsion Lab (JPL), the Glenn Research Center (GRC), the Langley Research Center (LaRC), and Aeroflex, Inc. over the last few years have worked to develop and test electro-mechanical hardware that will meet the stringent environmental demands of the moon, and which can also be leveraged for other challenging space exploration missions. Prototype actuators and electronics have been built and tested. Brushless DC actuators designed by Aeroflex, Inc have been tested with interface temperatures as low as 14 degrees Kelvin. Testing of the Aeroflex design has shown that a brushless DC motor with a single stage planetary gearbox can operate in low temperature environments for at least 120 million cycles (measured at motor) if long life is considered as part of the design. A motor control distributed electronics concept developed by JPL was built and operated at temperatures as low as -160 C, with many components still operational down to -245 C. Testing identified the components not capable of meeting the low temperature goal of -230 C. This distributed controller is universal in design with the ability to control different types of motors and read many different types of sensors. The controller form factor was designed to surround or be at the actuator. Communication with the slave controllers is accomplished by a bus, thus limiting the number of wires that must be routed to the extremity locations. Efforts have also been made to increase the power capability of these electronics for the ability to power and control actuators up to 2.5KW and still meet the environmental challenges. For commutation and control of the actuator, a resolver was integrated and tested with the actuator. Testing of this resolver demonstrated temperature limitations. Subsequent failure analysis isolated the low temperature failure mechanism and a design solution was negotiated with the manufacturer. Several years of work have resulted in specialized electro-mechanical hardware to meet extreme space exploration environments, a test history that verifies and finds limitations of the designs and a growing knowledge base that can be leveraged by future space exploration missions.

Mojarradi, Mohammad M.↗

NASA NTRS2019

Optical System Design and Integration of the Global Ecosystem Dynamics Investigation Lidar

The Global Ecosystem Dynamics Investigation (GEDI) instrument was designed, built, and tested in-house at NASA’s Goddard Space Flight Center and launched to the International Space Station (ISS) on December 5, 2018. GEDI is a multi-beam waveform LiDAR (light detection and ranging) designed to measure the Earth’s global tree height and canopy density using 8 laser beam ground tracks separated by roughly 600 meters. Given the ground coverage required and the 2 year mission duration, a unique optical design solution was developed. GEDI generates 8 ground sampling tracks from 3 transmitter systems viewed by a single receiver telescope, all while maximizing system optical efficiency and transmitter to receiver boresight alignment margin. The GEDI optical design, key optical components, and system level integration and testing are presented here. GEDI began 2 years of science operations in March 2019 and so far, it is meeting all of its key optical performance requirements and is returning outstanding science.

Integration↗

NASA NTRSDate not supplied

NASA's Composite Overwrap Lessons Learned on 40k Thrust Chamber Assemblies

Filament wound carbon fiber/polymer composite overwraps combined with additively manufactured (AM) copper alloy combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. The composite overwrap is a high strength-to-weight material and allows for significant weight reduction of the high-pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication time while offering structural robustness. Integrated AM/composite overwrap chamber assemblies using 2,000 lbf (2k) and 7,000 lbf (7k) thrust were successfully hot fire tested at NASA Marshall Space Flight Center (MSFC). These assemblies allowed the team to learn lessons related to the design, analysis, and manufacturing of these integrated assemblies. A final goal of the RAMPT project is to design and test a 40,000 lbf (40k) thrust chamber assembly. The40k chamber presented the team several new challenges including an integral inlet port in the main body of the composite overwrap. Through multiple iterations of manufacturing techniques, varied materials, and Non-Destructive Evaluations (NDE), many lessons were learned to obtain a final design solution that would not only allow for the interrupted port inlet but also allow for sufficient material margins for the most critically stressed part of the chamber. This paper will cover the manufacturing techniques exploring fabric designs to help subsidize the coverage in the areas left bare by the inlet port during the filament winding process and custom tooling needed for the final full chamber processing. The original material choice of bismaleimide (BMI) 5250-4 from the 7k chamber performed well for the extreme environment of hot fire testing but proved to be difficult with the increased scale and interrupted port design of the 40kchamber. Discussion in this paper will cover these changes, including evaluation of the design, comparison to the prior 2k and 7k designs, and show the final hardware that will be tested. One primary goal of this work and RAMPT project is to provide this development process and data to industry for infusion into future engine designs.

Filament Wound↗

NASA NTRS1994

System Design under Uncertainty: Evolutionary Optimization of the Gravity Probe-B Spacecraft

This paper discusses the application of evolutionary random-search algorithms (Simulated Annealing and Genetic Algorithms) to the problem of spacecraft design under performance uncertainty. Traditionally, spacecraft performance uncertainty has been measured by reliability. Published algorithms for reliability optimization are seldom used in practice because they oversimplify reality. The algorithm developed here uses random-search optimization to allow us to model the problem more realistically. Monte Carlo simulations are used to evaluate the objective function for each trial design solution. These methods have been applied to the Gravity Probe-B (GP-B) spacecraft being developed at Stanford University for launch in 1999, Results of the algorithm developed here for GP-13 are shown, and their implications for design optimization by evolutionary algorithms are discussed.

Pullen, Samuel P.↗

NASA NTRS2007

Application of Design Patterns in Refactoring Software Design

Refactoring software design is a method of changing software design while explicitly preserving its unique design functionalities. Presented approach is to utilize design patterns as the basis for refactoring software design. Comparison of a design solution will be made through C++ programming language examples to exploit this approach. Developing reusable component will be discussed, the paper presents that the construction of such components can diminish the added burden of both refactoring and the use of design patterns.

Baggs. Rjpda↗

NASA NTRS2007

Apply Design Patterns to Refactor Software Design

Baggs, Rhoda↗

NASA NTRS2008

100-LBF LO2/LCH4 - Reaction Control Engine Technology Development for Future Space Vehicles

The National Aeronautics and Space Administration (NASA) has identified liquid oxygen (LO2)/liquid methane (LCH4) propulsion systems as promising options for some future space vehicles. NASA issued a contract to Aerojet to develop a 100-lbf (445 N) LO2/LCH4 Reaction Control Engine (RCE) aimed at reducing the risk of utilizing a cryogenic reaction control system (RCS) on a space vehicle. Aerojet utilized innovative design solutions to develop an RCE that can ignite reliably over a broad range of inlet temperatures, perform short minimum impulse bits (MIB) at small electrical pulse widths (EPW), and produce excellent specific impulse (Isp) across a range of engine mixture ratios (MR). These design innovations also provide a start transient with a benign MR, ensuring good thrust chamber compatibility and long life. In addition, this RCE can successfully operate at MRs associated with main engines, enabling the RCE to provide emergency backup propulsion to minimize vehicle propellant load and overall system mass.

Robinson, Philip J.↗

NASA NTRS2008

100-Lb(f) LO2/LCH4 Reaction Control Engine Technology Development for Future Space Vehicles

Robinson, Philip J.↗

NASA NTRS1966

Commerical application of rocket engine turbopump technology

This paper describes how commercial pump technology was modified for rocket engine application by trading long life for low weight. The component life of typical turbopump components is presented, and the modes of failure will be discussed. A comparison of the basic commercial and rocket engine pump requirements such as flow, pressure, etc. is made. It is concluded that rocket engine pump technology can be applied directly only if similar basic requirements exist in emergency or stand-by equipment. The specific design requirements for rocket engine turbopumps are presented and the need for high speeds is explained by the weight-speed relationship and the optimum NPSH of the tank and pump system. The trend of required rocket engine pump discharge pressure and future operational requirements is predicted. The need for inducers and boost pumps in rocket engines is explained, and the results of the flat-plate-inducer cavitation therein are briefly presented. Design solutions and material selections for high-pressure pump housings, ultra-high tip speed impellers, and pump packaging are demonstrated. As a typical example of utilizing rocket engine technology for commercial application, a helicopter stand-by engine i shown. This standby engine is designed from existing rocket engine components, using JATO rockets as the prime energy source.

Turbopump↗

NASA NTRSDate not supplied

Impact-Identified Medical Capabilities with Largest Effect on Medical Risk for an Extended Duration Artemis Mission

Historically, identifying resources to include in a medical system has been based on heuristically guided clinical subject matter expert assessment. Probabilistic risk assessment (PRA) and tradespace analysis have the power to simplify and increase the fidelity of this traditional approach by providing initial risk estimates and system design solutions that fit within the specified constraints. This will be especially important as the increased mission complexity, distance from Earth, and duration of LDEMs is likely to drive an increase in mission medical risk. NASA’s Informing Mission Planning via Analysis of Complex Tradespaces tool (IMPACT) is designed to do just that. IMPACT uses an evidence based medical database of conditions likely to affect LDEM outcomes and a PRA computational engine to estimate how medical conditions and included medical capabilities affect mission outcomes. We identified the 10 medical conditions with the largest effect on medical risks and determined what medical system capabilities affected risk reduction the greatest.

Anderson A↗

NASA NTRS2014

Fault Management Design Strategies

Development of dependable systems relies on the ability of the system to determine and respond to off-nominal system behavior. Specification and development of these fault management capabilities must be done in a structured and principled manner to improve our understanding of these systems, and to make significant gains in dependability (safety, reliability and availability). Prior work has described a fundamental taxonomy and theory of System Health Management (SHM), and of its operational subset, Fault Management (FM). This conceptual foundation provides a basis to develop framework to design and implement FM design strategies that protect mission objectives and account for system design limitations. Selection of an SHM strategy has implications for the functions required to perform the strategy, and it places constraints on the set of possible design solutions. The framework developed in this paper provides a rigorous and principled approach to classifying SHM strategies, as well as methods for determination and implementation of SHM strategies. An illustrative example is used to describe the application of the framework and the resulting benefits to system and FM design and dependability.

systems engineering↗

NASA NTRS2007

Entry, Descent, and Landing Mission Design for the Crew Exploration Vehicle Thermal Protection System Qualification Flight Test

The TORCH team was challenged to generate the lowest cost mission design solution that meets the CEV aerothermal test objectives on a sub-scale flight article. The test objectives resulted from producing representative lunar return missions and observing the aerothermal envelopes of select surface locations on the CEV. From these aerothermal envelopes, two test boxes were established: one for high shear and one for high radiation. The unique and challenging trajectory design objective for the flight test was to fly through these aerothermal boxes in shear, pressure, heat flux, and radiation while also not over testing. These test boxes, and the max aerothermal limits, became the driving requirements for defining the mission design.

Ivanov, Mark↗

NASA NTRSDate not supplied

Integrated Design Results for the MSR DAC-0.0 Mars Ascent Vehicle

The NASA Mars Sample Return (MSR) Campaign endeavors to return Martian regolith, rock, and atmospheric samples to Earth for scientific study. One of many significant challenges to overcome in the return of these samples lies in transporting them from the Martian surface to space. In order to surmount this challenge, the Campaign has conceptualized the need for a Mars Ascent Vehicle (MAV) to perform this function and deliver Martian samples to orbit. There, the samples will be ejected and captured by a separate spacecraft for return to Earth. Many concepts for a MAV have existed in the past, but it has not been until now that an integrated, detailed design solution has been developed and analyzed. Preliminary assessments of the initial architecture examined multiple methods of propulsion. The team ultimately determined that a Two Stage to Orbit (TSTO) solid propulsion vehicle would provide the most effective performance and be the most technologically ready to support this mission. Following the decision to adopt a TSTO solid propelled vehicle, the first official Design Analysis Cycle, DAC-0.0, was performed in Spring 2020 to formally advance the fidelity of the vehicle to a maturity level acceptable for NASA Key Decision Point A (KDP-A). This paper describes the resultant MAV design concept developed as part of the DAC-0.0 study by the NASA Marshall Space Flight Center (MSFC), in association with the NASA Jet Propulsion Laboratory (JPL). The TSTO vehicle features two solid rocket motors, one powering each stage. Their thrust vectors are controlled with Thrust Vector Control (TVC) systems consisting of independent electromechanical actuators acting on gimballed nozzles. The vehicle is designed to deliver up to 0.47kg of Martian samples to a Mars circular orbit of 343km at 27° inclination. Due to the unique environmental conditions that this vehicle is required to operate in, the subsystem design teams were compelled to develop creative and unorthodox designs to ensure a successful mission. The detailed design and analysis of these subsystems are discussed in this paper and include topics on the MAV Guidance, Navigation, and Control (GNC); structures and mechanisms; integrated vehicle thermal; avionics and flight software; a hydrazine-based Reaction Control System (RCS); aerosciences; and vehicle assembly, integration, and test (AI&T) considerations, among others. Following the conclusion of the MAV DAC-0.0, additional alternative architecture concepts were also studied to further reduce the mass of the overall system. The results of these studies will also be examined in this paper.

Darius Yaghoubi↗