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NASA NTRSDate not supplied

Lessons Learned from Large-Scale Aerospace Structural Testing

Large-scale testing of aerospace structures is frequently the final step in a development project to validate the structural performance, and that typically involves a large cost and time investment. In order to ensure that the testing provides the required data, avoiding errors that can result in an unsuccessful test and failure to meet objectives is critical. Presented herein are five lessons learned to provide insight to those conducting tests in order to help them avoid known pitfalls that may result in an unsuccessful test. Five subject large-scale tests are described, and include two composite wing tests, a composite hybrid-wing body center section test, a full-scale 27.5-ft diameter metallic barrel test, and an 8-ft diameter metallic barrel test. Problems identified during the testing and mitigation approaches to solve the problems are presented, then the lessons learned are summarized.

Lessons Learned↗

NASA NTRSDate not supplied

X-57 Flight Systems Integration Path

The foundation for a safe and successful flight test of the National Aeronautics and Space Administration (NASA) X-57 Maxwell all-electric experimental airplane, or any X-Plane, is comprehensive system testing on the ground. This test campaign includes verification and validation (V&V) that the integrated system operates as designed and expected, as well as understanding how the system reacts and responds to failures that can occur during flight by performing failure modes and effects testing (FMET). The aircraft should be in the final flight configuration for these test activities because any modifications, even those that appear insignificant, could affect test outcomes. Although the plan was to perform V&V and FMET testing once the airplane was in the flight configuration, due to multiple component redesigns, concurrent software development, and other problems with on-aircraft testing, the X-57 Maxwell never made it into a full-flight configuration. As a result, a build-up approach was followed to test software and hardware as they became ready in order to continue making progress wherever possible. Using this approach revealed problems with the hardware and software faster than waiting for a full-flight configuration, allowing solutions to be found more quickly and in parallel with other project tasks. Other than unloaded motor testing in a lab setting, the only other test setup was on the airplane itself. On-aircraft testing was preferrable in order to test things as close to a flight configuration as possible but was time consuming due to the requirements for testing on the airplane. To overcome some of the on-aircraft barriers, off-aircraft test configurations, such as the Systems Integration Laboratory (SIL) and hardware-in-the-loop (HIL) setups, were used, but each of these setups had limitations to be considered. As a result, solutions found in the SIL or HIL configurations did not always work as expected on the airplane, resulting in an iterative process between on- and off-aircraft testing to find the final solution. Having a dedicated test platform such as an iron bird that closely represents the aircraft - without flight hardware - would have been the most effective off-aircraft test setup, which could have allowed the project to save time and money and potentially reach flight. This paper will highlight the V&V and FMET considerations and testing prerequisites, the build-up approaches to both software and system testing, the benefits and drawbacks to different test configurations, as well as battery testing and operations.

Kassidy M. Mclaughlin↗

NASA NTRSDate not supplied

X-57 Flight Systems Integration Path

Kassidy McLaughlin↗

NASA NTRS2008

Reconfigurable HIL Testing of Earth Satellites

In recent years, hardware-in-the-loop (HIL) testing has carved a strong niche in several industries, such as automotive, aerospace, telecomm, and consumer electronics. As desktop computers have realized gains in speed, memory size, and data storage capacity, hardware/software platforms have evolved into high performance, deterministic HIL platforms, capable of hosting the most demanding applications for testing components and subsystems. Using simulation software to emulate the digital and analog I/O signals of system components, engineers of all disciplines can now test new systems in realistic environments to evaluate their function and performance prior to field deployment. Within the Aerospace industry, space-borne satellite systems are arguably some of the most demanding in terms of their requirement for custom engineering and testing. Typically, spacecraft are built one or few at a time to fulfill a space science or defense mission. In contrast to other industries that can amortize the cost of HIL systems over thousands, even millions of units, spacecraft HIL systems have been built as one-of-a-kind solutions, expensive in terms of schedule, cost, and risk, to assure satellite and spacecraft systems reliability. The focus of this paper is to present a new approach to HIL testing for spacecraft systems that takes advantage of a highly flexible hardware/software architecture based on National Instruments PXI reconfigurable hardware and virtual instruments developed using LabVIEW. This new approach to HIL is based on a multistage/multimode spacecraft bus emulation development model called Reconfigurable Hardware In-the-Loop or RHIL.

Source record↗

NASA NTRS2002

Outer planet spacecraft temperature testing and analysis

Unmanned spacecraft flown on missions to the outer planets of the solar system have included flybys, planetary orbiters, and atmospheric probes during the last three decades. The thermal design, test, and analysis approach applied to these spacecraft evolved from the passive thermal designs applied to the earlier lunar and interplanetary spacecraft. The inflight temperature data from representative sets of engineering subsystems and science instruments from a subset of these spacecraft are compared to those obtained during the ground test programs and from the prelaunch predictions. Several lessons are presented with specific recommendations for considerations for new projects to aid in the planning of cost effective temperature design, test, and analysis programs.

temperature testing planetary spacecraft Voyager G↗

NASA NTRS2007

High-Rate Wireless Airborne Network Demonstration (HiWAND) Flight Test Results

An increasing number of flight research and airborne science experiments now contain network-ready systems that could benefit from a high-rate bidirectional air-to-ground network link. A prototype system, the High-Rate Wireless Airborne Network Demonstration, was developed from commercial off-the-shelf components while leveraging the existing telemetry infrastructure on the Western Aeronautical Test Range. This approach resulted in a cost-effective, long-range, line-of-sight network link over the S and the L frequency bands using both frequency modulation and shaped-offset quadrature phase-shift keying modulation. This paper discusses system configuration and the flight test results.

Franz, Russell↗

NASA NTRS2008

High-Rate Wireless Airborne Network Demonstration (HiWAND) Flight Test Results

An increasing number of flight research and airborne science experiments now contain network-ready systems that could benefit from a high-rate bidirectional air-to-ground network link. A prototype system, the High-Rate Wireless Airborne Network Demonstration, was developed from commercial off-the-shelf components while leveraging the existing telemetry infrastructure on the Western Aeronautical Test Range. This approach resulted in a cost-effective, long-range, line-of-sight network link over the S and the L frequency bands using both frequency modulation and shaped-offset quadrature phase-shift keying modulation. This report discusses system configuration and the flight test results.

Franz, Russell↗

NASA NTRS2023

Lessons Learned from Large-Scale Aerospace Structural Testing

Large-scale testing of aerospace structures is frequently the final step in a development project to validate the structural performance, and that step typically involves a large cost and time investment. To ensure that the testing provides the required data, avoiding errors that can result in an unsuccessful test and failure to meet objectives is critical. Five lessons learned are presented herein to provide insight to those conducting tests in order to help them avoid known pitfalls that may result in an unsuccessful test. Five large-scale tests are described, and include two composite wing tests, a composite hybrid-wing body center section test, a full-scale 27.5-ft diameter metallic barrel test, and an 8-ft diameter metallic barrel test. Problems identified during the testing and mitigation approaches to solve the problems are presented, then the lessons learned are identified and discussed.

Lessons Learned↗

DOE OSTI2021

Experimental Validation of Subsystem Models for a Novel Variable Displacement Hydraulic Motor

A novel, variable displacement, low-speed high-torque hydraulic motor is being developed that is expected to be highly efficient across a broad operating range. To ensure the final hardware achieves the expected performance, the models used in the development of the motor must be experimentally validated and revised, as necessary. The specific focus in this work is on mechanical energy loss models that were used to guide the design of a single-cylinder motor prototype and on experimental tests used for model validation. Ideally each model, whether friction loss in a piston/cylinder interface or energy loss due to leakage in a valve , would be individually validated by an independent test. This granular approach would remove any question of where the error lies and result in highly accurate models. However, many motor components have multiple forms of energy loss, creating difficulty in validating individual losses. Additionally, it is not physically realizable to divide many components into an individual model equivalent test. Testing the motor as a full assembly is possible, but pinpointing the source of discrepancies between the model and the hardware becomes difficult with dozens of models potentially being partially responsible. A compromise was found by separating the motor into functional component groups that are characterized by the type of loss and ability to test each subcomponent independently. By checking for correlation between test observations and model predictions, revisions could be implemented into the models. This allows future solutions to be more accurately predicted in the design phase to drive the design of better machines.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2020

Short-wavelength-sensitive 2 (Sws2) visual photopigment models combined with atomistic molecular simulations to predict spectral peaks of absorbance

For many species, vision is one of the most important sensory modalities for mediating essential tasks that include navigation, predation and foraging, predator avoidance, and numerous social behaviors. The vertebrate visual process begins when photons of the light interact with rod and cone photoreceptors that are present in the neural retina. Vertebrate visual photopigments are housed within these photoreceptor cells and are sensitive to a wide range of wavelengths that peak within the light spectrum, the latter of which is a function of the type of chromophore used and how it interacts with specific amino acid residues found within the opsin protein sequence. Minor differences in the amino acid sequences of the opsins are known to lead to large differences in the spectral peak of absorbance (i.e. the λ max value). In our prior studies, we developed a new approach that combined homology modeling and molecular dynamics simulations to gather structural information associated with chromophore conformation, then used it to generate statistical models for the accurate prediction of λ max values for photopigments derived from Rh1 and Rh2 amino acid sequences. In the present study, we test our novel approach to predict the λ max of phylogenetically distant Sws2 cone opsins. To build a model that can predict the λ max using our approach presented in our prior studies, we selected a spectrally-diverse set of 11 teleost Sws2 photopigments for which both amino acid sequence information and experimentally measured λ max values are known. The final first-order regression model, consisting of three terms associated with chromophore conformation, was sufficient to predict the λ max of Sws2 photopigments with high accuracy. This study further highlights the breadth of our approach in reliably predicting λ max values of Sws2 cone photopigments, evolutionary-more distant from template bovine RH1, and provided mechanistic insights into the role of known spectral tuning sites.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS2002

Design and Testing of Improved Spacesuit Shielding Components

In prior studies of the current Shuttle Spacesuit (SSA), where basic fabric lay-ups were tested for shielding capabilities, it was found that the fabric portions of the suit give far less protection than previously estimated due to porosity and non-uniformity of fabric and LCVG components. In addition, overall material transmission properties were less than optimum. A number of alternate approaches are being tested to provide more uniform coverage and to use more efficient materials. We will discuss in this paper, recent testing of new material layups/configurations for possible use in future spacesuit designs.

Ware, J.↗

DOE OSTI2020

Operator evolution from the similarity renormalization group and the Magnus expansion

The Magnus expansion is an efficient alternative to solving similarity renormalization group (SRG) flow equations with high-order, memory-intensive ordinary differential equation solvers. The numerical simplifications it offers for operator evolution are particularly valuable for in-medium SRG calculations, though challenges remain for difficult problems involving intruder states. Here we test the Magnus approach in an analogous but more accessible situation, which is the free-space SRG treatment of the spurious bound states arising from a leading-order chiral effective field theory (EFT) potential with very high cutoffs. In this work, we show that the Magnus expansion passes these tests and then use the investigations as a springboard to address various aspects of operator evolution that have renewed relevance in the context of the scale and scheme dependence of nuclear processes. These aspects include SRG operator flow with band- versus block-diagonal generators, universality for chiral EFT Hamiltonians and associated operators with different regularization schemes, and the impact of factorization arising from scale separation. Implications for short-range correlations physics and the possibilities for reconciling high- and low-resolution treatments of nuclear structure and reactions are discussed.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS2003

Precision Agriculture: Changing the Face of Farming

To a large extent our work has grown out of the remote sensing technology and conceptual framework developed by geologists. For example the drive to look at the physics of reflectance and atmospheric corrections is rooted in work done in the early 1980s by the United States Geological Survey and NASA. Our work on emissivity and thermal behavior of plants pulls on research done using the Thermal Infrared Multispectral Scanner, an instrument originally conceived for geologic applications. Even our ability to geometrically map the airborne imagery onto the globe was explicitly developed because of need to map sediment flow patterns in along the coast of Louisiana. Growing from this base we have learned much in the last few years and believe our integration of geologic remote sensing with the other fields of expertise was a wise investment. Clearly none of the specialties alone could develop, let alone test, the basic approach we are now finding so powerful. This is the path that will ultimately give the information needed by the farmer. We also recognize how small a portion of the total problem has been solved. Having developed the basic logic, built proto-type tools and performed initial tests everything else remains to be done. And problems, scientific and practical, are everywhere. We have not established sensitivities. We have not robustly segregated the contributions of crop residue, soil moisture, shadows, plant and soil to the energy leaving the surface. What we do is extremely expensive and difficult. It is experimental in methodology and uses research oriented tools. We are constantly alive to the practicality of moving our results into commercial applications. We know another airborne instrument will have to be available. Atmospheric parameters will have to be measured automatically. The software will have to be re-written for speed. At times the list of problems seems endless. But the potential is also enormous. Agriculture is a huge portion of our economy. Just a one percent increase in efficiency is a $2,000,000 change. We all depend on farmers, literally for the bread we eat. No other activity of man even has an impact on the land that farming has. If application of precision agriculture can nelp farmers manage their land better, we all may benefit.

Rickman, D.↗

NASA NTRS2012

Current CFD Practices in Launch Vehicle Applications

The quest for sustained space exploration will require the development of advanced launch vehicles, and efficient and reliable operating systems. Development of launch vehicles via test-fail-fix approach is very expensive and time consuming. For decision making, modeling and simulation (M&S) has played increasingly important roles in many aspects of launch vehicle development. It is therefore essential to develop and maintain most advanced M&S capability. More specifically computational fluid dynamics (CFD) has been providing critical data for developing launch vehicles complementing expensive testing. During the past three decades CFD capability has increased remarkably along with advances in computer hardware and computing technology. However, most of the fundamental CFD capability in launch vehicle applications is derived from the past advances. Specific gaps in the solution procedures are being filled primarily through "piggy backed" efforts.on various projects while solving today's problems. Therefore, some of the advanced capabilities are not readily available for various new tasks, and mission-support problems are often analyzed using ad hoc approaches. The current report is intended to present our view on state-of-the-art (SOA) in CFD and its shortcomings in support of space transport vehicle development. Best practices in solving current issues will be discussed using examples from ascending launch vehicles. Some of the pacing will be discussed in conjunction with these examples.

Kwak, Dochan↗

NASA NTRS1998

Simulation of Ultra-Small MOSFETs Using a 2-D Quantum-Corrected Drift-Diffusion Model

The continued down-scaling of electronic devices, in particular the commercially dominant MOSFET, will force a fundamental change in the process of new electronics technology development in the next five to ten years. The cost of developing new technology generations is soaring along with the price of new fabrication facilities, even as competitive pressure intensifies to bring this new technology to market faster than ever before. To reduce cost and time to market, device simulation must become a more fundamental, indeed dominant, part of the technology development cycle. In order to produce these benefits, simulation accuracy must improve markedly. At the same time, device physics will become more complex, with the rapid increase in various small-geometry and quantum effects. This work describes both an approach to device simulator development and a physical model which advance the effort to meet the tremendous electronic device simulation challenge described above. The device simulation approach is to specify the physical model at a high level to a general-purpose (but highly efficient) partial differential equation solver (in this case PROPHET, developed by Lucent Technologies), which then simulates the model in 1-D, 2-D, or 3-D for a specified device and test regime. This approach allows for the rapid investigation of a wide range of device models and effects, which is certainly essential for device simulation to catch up with, and then stay ahead of, electronic device technology of the present and future. The physical device model used in this work is the density-gradient (DG) quantum correction to the drift-diffusion model [Ancona, Phys. Rev. B 35(5), 7959 (1987)]. This model adds tunneling and quantum smoothing of carrier density profiles to the drift-diffusion model. We used the DG model in 1-D and 2-D (for the first time) to simulate both bipolar and unipolar devices. Simulations of heavily-doped, short-base diodes indicated that the DG quantum corrections do not have a large effect on the IN characteristics of electronic devices without heteroj unction s. On the other hand, ultra-small MOSFETs certainly exhibit important quantum effects that the DG model will include: quantum repulsion of the inversion and gate charges from the oxide interfaces, and quantum tunneling through thin gate oxides. We present initial results of 2-D DG simulations of ultra-small MOSFETs. Subtle but important issues involving the specification of the model, boundary conditions, and interface constraints for DG simulation of MOSFETs will also be illuminated.

Biegal, Bryan A.↗

NASA NTRS2005

Learning Lessons from the X-37 Project

The X-37 was planned as an automated vehicle capable of flight-testing new aerospace technologies in combined environments that are beyond the capability of existing ground or flight platforms. Flight demonstration with the X-37 architecture and configuration in relevant environments was planned to reduce the risk of developing launch vehicle technologies for sustainable, affordable exploration and other aerospace applications. Current plans are for the X-37 Approach and Landing Test Vehicle (ALTV) to be atmospheric tested in 2005 from Scaled Composite's White Knight carrier aircraft at up to 40,000 feet over California's Mojave Spaceport, with and turnaround maintenance performed. The fight Operations Control Center will conduct the mission, using a streamlined operations concept. Taxi-tow and captive-carry tests will be conducted prior to the atmospheric-test series. Sponsored by the Defense Advanced Research Projects Agency (DARPA) with NASA participation, technical objectives are to: (1) mature Computed Air Data System/Remote Pressure Sensor technology, (2) manage energy during Terminal Area Energy Management/Heading Alignment Cone maneuvers, and (3) validate the aerodatabase. The X-37 Project began in 1999 under a cooperative agreement as an element of NASA's Future X Program and transitioned to a NASA Research Announcement under the Space Launch Initiative. In mid-2004, NASA transferred ownership to DARPA, with its heritage of performing high-risk, high-payoff research and development. NASA contributes technical expertise, including risk analysis and system integration. The Boeing Company is the prime contractor, with nationwide suppliers. This recent partnership exemplifies the synergy attainable when NASA Centers, other Government agencies, and industry work together toward a common goal - contributing to the knowledge base for U.S. exploration and other aerospace endeavors. The X-37 team represents a range of space transportation disciplines - from engineering to management. Some members have been with the project since its inception. All have gained priceless experience during the design, manufacturing, and testing of the ALTV, as well as through developing advanced orbital flight technologies, such as state-of-the-art Thermal Protection Systems and hot structures. Throughout this process, the X-37 Project team captures lessons that are directly applicable to other such efforts. The upcoming ALTV flights offer another dimension of data and first-hand experience that will prove invaluable to those designing new generations of reusable spacecraft. And ongoing technology developments will expand the aerospace knowledge base. Delivering prototype hardware is always a risky proposition. During the course of the X-37 effort, the team has experienced many challenging opportunities, delivering significant accomplishments and learning numerous lessons in the process. The ability to manage the risk landscape is key to overcoming obstacles, especially technical hurdles that are encountered in progressing hardware from design to flight. The approach to managing risk under this partnership is evolving but, in general, the team allocates resources to reduce the likelihood of severe-consequence risks, thus maximizing mission success and ensuring that the X-37 Project delivers value to its stakeholders. As the team sharpens its focus on operations, it continues to contribute knowledge to those who would undertake high-risk, high-payoff research and development and provides valuable experience to implement the exploration vision.

Turner, Susan↗

NASA NTRS2005

Learning Lessons from the X-37 Project

The X-37 was planned as an automated vehicle capable of flight-testing new aerospace technologies in combined environments that are beyond the capability of existing ground or flight platforms. Flight demonstration with the X-37 architecture and configuration in relevant environments was planned to reduce the risk of developing launch vehicle technologies for sustainable, affordable exploration and other aerospace applications. Current plans are for the X-37 Approach and Landing Test Vehicle (ALTV) to be atmospheric tested in 2005 from Scaled Composite s White Knight carrier aircraft at up to 40,000 feet over California's Mojave Spaceport, with landing and turnaround maintenance performed. The Flight Operations Control Center will conduct the mission, using a streamlined operations concept. Taxi-tow and captive-carry tests will be conducted prior to the atmospheric-test series. Sponsored by the Defense Advanced Research Projects Agency (DARPA) with NASA participation, technical objectives are to: (1) mature Computed Air Data System/Remote Pressure Sensor technology, (2) manage energy during Terminal Area Energy Management/Heading Alignment Cone maneuvers, and (3) validate the aerodatabase. The X-37 Project began in 1999 under a cooperative agreement as an element of NASA's Future X Program and transitioned to a NASA Research Announcement under the Space Launch Initiative. In mid-2004, NASA transferred ownership to DARPA, with its heritage of performing high-risk, high-payoff research and development (R&D). NASA contributes technical expertise, including risk analysis and system integration. The Boeing Company is the prime contractor, with nationwide suppliers. This partnership exemplifies the synergy attainable when NASA Centers, other Government agencies, and industry work together toward a common goal - contributing to the knowledge base for U.S. exploration and other aerospace endeavors. The X-37 team represents a range of space transportation disciplines - from engineering to management. Some members have been with the project since its inception. All have gained priceless experience during the design, manufacturing, and testing of the ALTV, as well as through developing advanced orbital flight technologies, such as state-of-the-art Thermal Protection Systems and hot structures. Throughout this process, the X-37 Project team captures lessons that are directly applicable to other such efforts. The upcoming ALTV flights offer another dimension of data and first-hand experience that will prove invaluable to those designing new generations of reusable spacecraft. And ongoing technology developments will expand the aerospace knowledge base. Delivering prototype hardware is always a risky proposition. During the course of this effort, the X-37 team has experienced many challenging opportunities, delivering significant accomplishments and learning numerous lessons in the process. The ability to manage the risk landscape is key to overcoming obstacles, especially technical hurdles that are encountered in progressing hardware from design to flight. The approach to managing risk under this partnership is evolving but, in general, the team allocates resources to reduce the likelihood of severe-consequence risks, thus maximizing mission success and ensuring that the X-37 Project delivers value to its stakeholders. As the team sharpens its focus on operations, it continues to contribute knowledge to those who would undertake high-risk, high-payoff R&D and provides valuable experience to implement the Vision for Space Exploration.

Turner, Susan↗

DOE OSTI2021

Exploration of multifidelity UQ sampling strategies for computer network applications.

Network modeling is a powerful tool to enable rapid analysis of complex systems that can be challenging to study directly using physical testing. Here, two approaches are considered: emulation and simulation. The former runs real software on virtualized hardware, while the latter mimics the behavior of network components and their interactions in software. Although emulation provides an accurate representation of physical networks, this approach alone cannot guarantee the characterization of the system under realistic operative conditions. Operative conditions for physical networks are often characterized by intrinsic variability (payload size, packet latency, etc.) or a lack of precise knowledge regarding the network configuration (bandwidth, delays, etc.); therefore uncertainty quantification (UQ) strategies should be also employed. UQ strategies require multiple evaluations of the system with a number of evaluation instances that roughly increases with the problem dimensionality, i.e., the number of uncertain parameters. It follows that a typical UQ workflow for network modeling based on emulation can easily become unattainable due to its prohibitive computational cost. In this paper, a multifidelity sampling approach is discussed and applied to network modeling problems. The main idea is to optimally fuse information coming from simulations, which are a low-fidelity version of the emulation problem of interest, in order to decrease the estimator variance. By reducing the estimator variance in a sampling approach it is usually possible to obtain more reliable statistics and therefore a more reliable system characterization. Several network problems of increasing difficulty are presented. For each of them, the performance of the multifidelity estimator is compared with respect to the single fidelity counterpart, namely, Monte Carlo sampling. For all the test problems studied in this work, the multifidelity estimator demonstrated an increased efficiency with respect to MC.

97 MATHEMATICS AND COMPUTING↗