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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1972

A method of hardware qualification for flight by analyses, similarity and integrated testing

The results are described of a study on four pieces of flight hardware from the Saturn 1U and S-4B stages to determine whether the objectives of the formal qualification tests on that hardware could have been obtained within that program by methods other than performing the qualification tests. These methods include qualification by analyses, similarity and integrated testing, i.e., distribution of the objectives among the other tests in the program. It was found that it is feasible to delete the requirements for formal qualification testing provided that it is accomplished early in the program to allow adequate planning for accomplishing the qualification objectives by other means. Additionally, a scorekeeping system was defined that is simple, straightforward, easy to implement. This scorekeeping system provides complete visibility of equivalent qualification status at any point during the program. A set of groundrules for implementing this study was established as a result of findings on the specific items of hardware studied.

Andriulli, J. B.↗
NASA NTRS1999

Benefits of Force Limiting Vibration Testing

Force limited random vibration testing is used at NASA John Glenn Research Center (formerly NASA Lewis Research Center) for qualifying aerospace hardware for flight. The benefit of force limiting testing is that it limits overtesting of flight hardware, by controlling input force and acceleration from the shaker (dual control) to the test article. The purpose of force limiting is to replicate the test article resonant response for the actual flight mounting condition. The force limiting testing technology has been implemented at the Jet Propulsion Laboratory for the past 10 years on various spacecraft testing programs. The Cassini mission to Saturn, most notably, utilized force limiting vibration testing as part of the spacecraft system level vibration testing. NASA John Glenn Research Center is responsible for microgravity combustion and fluid science research on the Shuttle and the International Space Station. Qualification testing of delicate and vibration sensitive science instrumentation is particularly challenging to successfully qualify for flight. In order to facilitate the testing process, force limiting has been implemented to minimize overtesting of flight hardware. This paper will address recent flight camera testing (qualification random vibration and strength testing) for the Combustion Module-2 mission and the impact of Semi-empirical Method force limits.

McNelis, Mark E.↗
NASA NTRS2011

Component-Level Electronic-Assembly Repair (CLEAR) System Architecture

This document captures the system architecture for a Component-Level Electronic-Assembly Repair (CLEAR) capability needed for electronics maintenance and repair of the Constellation Program (CxP). CLEAR is intended to improve flight system supportability and reduce the mass of spares required to maintain the electronics of human rated spacecraft on long duration missions. By necessity it allows the crew to make repairs that would otherwise be performed by Earth based repair depots. Because of practical knowledge and skill limitations of small spaceflight crews they must be augmented by Earth based support crews and automated repair equipment. This system architecture covers the complete system from ground-user to flight hardware and flight crew and defines an Earth segment and a Space segment. The Earth Segment involves database management, operational planning, and remote equipment programming and validation processes. The Space Segment involves the automated diagnostic, test and repair equipment required for a complete repair process. This document defines three major subsystems including, tele-operations that links the flight hardware to ground support, highly reconfigurable diagnostics and test instruments, and a CLEAR Repair Apparatus that automates the physical repair process.

Oeftering, Richard C.↗
NASA NTRS2022

Electrical Ground Support Equipment for the Sampling Caching System of the Mars 2020 Rover

In this work we describe in detail the architecture, design, testing and operation of the Electrical Ground Support Equipment (EGSE) “Blue Box” used to test and validate the Sampling Caching System (SCS) of the Mars 2020 Perseverance rover. The Blue Box architecture is centered around COTS motor controllers and COTS input-output modules communicating over an EtherCAT bus. A custom, low-level safety subsystem ensures no harm can be done to the flight articles. The modular architecture of the EGSE reduces cost and complexity while expediting assembly time. The Blue Box drives the 19 actuators of the SCS which span the main robotic arm, the corer system, the internal sample handling arm, the sample tube sealing system and the gas dust removal tool; mimicking the Rover Motor Control Assembly (RMCA). Due to the limited availability of RMCA’s, the EGSE enabled and performed the bulk of testing activities for SCS. The majority of the SCS actuators are composed of a 3-phase DC brushless motors, hall sensors for commutation, dual resolvers for output angular measurement, brakes, heaters and platinum thermistors. Additionally, the EGSE read 12 strain gauges forming part of a force torque sensor, and switches used for external positioning references. Over the 3-year span of the V&V campaign for the SCS, over 32 EGSE systems were built, tested and deployed to test venues at JPL and externally. The EGSE tested several families of the SCS subsystem, ranging from engineering units, life test units and two flight units. Test venues that this EGSE supported included lab benches, ultra-clean cleanrooms, ATLO facilities, and thermal vacuum chambers. Together with the test software systems, SSDEV and SSDEV-ECAT, the Blue Box EGSE enabled the team to efficiently test flight hardware and flight software together. We go over the safety features and fault management techniques employed to protect flight hardware. The effects of the long, 50-feet, EGSE harnesses on motor performance, EMI, electrical noise, and motor control performance are explained. Mitigations to these unwanted effects, including shielding strategy and inductance compensation, are summarized. We go over an excerpt of notable anomalies that this EGSE suffered through its operation, along with investigations and resolutions. Lessons learned, areas of improvement as part of future work, and recommendations for future implementations for similar EGSE’s, are shared.

Levine, Dan↗
NASA NTRS2004

The Art of Space Flight Exercise Hardware: Design and Implementation

The design of space flight exercise hardware depends on experience with crew health maintenance in a microgravity environment, history in development of flight-quality exercise hardware, and a foundation for certifying proper project management and design methodology. Developed over the past 40 years, the expertise in designing exercise countermeasures hardware at the Johnson Space Center stems from these three aspects of design. The medical community has steadily pursued an understanding of physiological changes in humans in a weightless environment and methods of counteracting negative effects on the cardiovascular and musculoskeletal system. The effects of weightlessness extend to the pulmonary and neurovestibular system as well with conditions ranging from motion sickness to loss of bone density. Results have shown losses in water weight and muscle mass in antigravity muscle groups. With the support of university-based research groups and partner space agencies, NASA has identified exercise to be the primary countermeasure for long-duration space flight. The history of exercise hardware began during the Apollo Era and leads directly to the present hardware on the International Space Station. Under the classifications of aerobic and resistive exercise, there is a clear line of development from the early devices to the countermeasures hardware used today. In support of all engineering projects, the engineering directorate has created a structured framework for project management. Engineers have identified standards and "best practices" to promote efficient and elegant design of space exercise hardware. The quality of space exercise hardware depends on how well hardware requirements are justified by exercise performance guidelines and crew health indicators. When considering the microgravity environment of the device, designers must consider performance of hardware separately from the combined human-in-hardware system. Astronauts are the caretakers of the hardware while it is deployed and conduct all sanitization, calibration, and maintenance for the devices. Thus, hardware designs must account for these issues with a goal of minimizing crew time on orbit required to complete these tasks. In the future, humans will venture to Mars and exercise countermeasures will play a critical role in allowing us to continue in our spirit of exploration. NASA will benefit from further experimentation on Earth, through the International Space Station, and with advanced biomechanical models to quantify how each device counteracts specific symptoms of weightlessness. With the continued support of international space agencies and the academic research community, we will usher the next frontier in human space exploration.

Beyene, Nahom M.↗
NASA NTRS1997

High-Flux, High-Temperature Thermal Vacuum Qualification Testing of a Solar Receiver Aperture Shield

As part of the International Space Station (ISS) Phase 1 program, NASA Lewis Research Center (LERC) and the Russian Space Agency (RSA) teamed together to design, build and flight test the world's first orbital Solar Dynamic Power System (SDPS) on the Russian space station Mir. The Solar Dynamic Flight Demonstration (SDFD) program was to operate a nominal 2 kWe SDPS on Mir for a period up to 1-year starting in late 1997. Unfortunately, the SDFD mission was demanifested from the ISS phase 1 shuttle program in early 1996. However, substantial flight hardware and prototypical flight hardware was built including a heat receiver and aperture shield. The aperture shield comprises the front face of the cylindrical cavity heat receiver and is located at the focal plane of the solar concentrator. It is constructed of a stainless steel plate with a 1-m outside diameter, a 0.24-m inside diameter and covered with high-temperature, refractory metal Multi-Foil Insulation (MFI). The aperture shield must minimize heat loss from the receiver cavity, provide a stiff, high strength structure to accommodate shuttle launch loads and protect receiver structures from highly concentrated solar fluxes during concentrator off-pointing events. To satisfy Mir operational safety protocols, the aperture shield was required to accommodate direct impingement of the intensely concentrated solar image for a 1-hour period. To verify thermal-structural durability under the anticipated high-flux, high-temperature loading, an aperture shield test article was constructed and underwent a series of two tests in a large thermal vacuum chamber configured with a reflective, point-focus solar concentrator and a solar simulator. The test article was positioned near the focal plane and exposed to concentrated solar flux for a period of 1-hour. In the first test, a near equilibrium temperature of 1862 K was attained in the center of the shield hot spot. In the second test, with increased incident flux, a near equilibrium temperature of 2072 K was achieved. The aperture shield sustained no visible damage as a result of the exposures. This paper describes the aperture shield thermal-vacuum qualification test program including the test article, test facility, procedures, data collection, test success criteria, results and conclusions.

Kerslake, Thomas W.↗
NASA NTRS2009

Contamination Examples and Lessons from Low Earth Orbit Experiments and Operational Hardware

Flight experiments flown on the Space Shuttle, the International Space Station, Mir, Skylab, and free flyers such as the Long Duration Exposure Facility, the European Retrievable Carrier, and the EFFU, provide multiple opportunities for the investigation of molecular contamination effects. Retrieved hardware from the Solar Maximum Mission satellite, Mir, and the Hubble Space Telescope has also provided the means gaining insight into contamination processes. Images from the above mentioned hardware show contamination effects due to materials processing, hardware storage, pre-flight cleaning, as well as on-orbit events such as outgassing, mechanical failure of hardware in close proximity, impacts from man-made debris, and changes due to natural environment factors.. Contamination effects include significant changes to thermal and electrical properties of thermal control surfaces, optics, and power systems. Data from several flights has been used to develop a rudimentary estimate of asymptotic values for absorptance changes due to long-term solar exposure (4000-6000 Equivalent Sun Hours) of silicone-based molecular contamination deposits of varying thickness. Recommendations and suggestions for processing changes and constraints based on the on-orbit observed results will be presented.

Pippin, Gary↗
NASA NTRS2000

Managing Risk for Thermal Vacuum Testing of the International Space Station Radiators

The International Space Station (ISS) is designed with large deployable radiator panels that are used to reject waste heat from the habitation modules. Qualification testing of the Heat Rejection System (HRS) radiators was performed using qualification hardware only. As a result of those tests, over 30 design changes were made to the actual flight hardware. Consequently, a system level test of the flight hardware was needed to validate its performance in the final configuration. A full thermal vacuum test was performed on the flight hardware in order to demonstrate its ability to deploy on-orbit. Since there is an increased level of risk associated with testing flight hardware, because of cost and schedule limitations, special risk mitigation procedures were developed and implemented for the test program, This paper introduces the Continuous Risk Management process that was utilized for the ISS HRS test program. Testing was performed in the Space Power Facility at the NASA Glenn Research Center, Plum Brook Station located in Sandusky, Ohio. The radiator system was installed in the 100-foot diameter by 122-foot tall vacuum chamber on a special deployment track. Radiator deployments were performed at several thermal conditions similar to those expected on-orbit using both the primary deployment mechanism and the back-up deployment mechanism. The tests were highly successful and were completed without incident.

Carek, Jerry A.↗
NASA NTRS2001

Development of the Electron Drift Instrument (EDI) for Cluster

The Electron Drift Instrument (EDI) is a new technique for measuring electric fields in space by detecting the effect on weak beams of test electrons. This U.S. portions of the technique, flight hardware, and flight software were developed for the Cluster mission under this contract. Dr. Goetz Paschmann of the Max Planck Institute in Garching, Germany, was the Principle Investigator for Cluster EDI. Hardware for Cluster was developed in the U.S. at the University of New Hampshire, Lockheed Palo Alto Research Laboratory, and University of California, San Diego. The Cluster satellites carrying the original EDI instruments were lost in the catastrophic launch failure of first flight of the Arianne-V rocket in 1996. Following that loss, NASA and ESA approved a rebuild of the Cluster mission, for which all four satellites were successfully launched in the Summer of 2000. Limited operations of EDI were also obtained on the Equator-S satellite, which was launched in December, 1997. A satellite failure caused a loss of the Equator-S mission after only 5 months, but these operations were extremely valuable in learning about the characteristics and operations of the complex EDI instrument. The Cluster mission, satellites, and instruments underwent an extensive on-orbit commissioning phase in the Fall of 2000, carrying over through January 2001. During this period all elements of the instruments were checked and careful measurements of inter-experiments interferences were made. EDI is currently working exceptionally well in orbit. Initial results verify that all aspects of the instrument are working as planned, and returning highly valuable scientific information. The first two papers describing EDI on-orbit results have been submitted for publication in April, 2001. The principles of the EDI technique, and its implementation on Cluster are described in two papers by Paschmann et al., attached as Appendices A and B. The EDI presentation at the formal Cluster Commissioning Review, held at ESA Headquarters in Paris, is attached as Appendix C.

Quinn, Jack↗
NASA NTRS1989

First incremental buy for Increment 2 of the Space Transportation System (STS)

Thiokol manufactured and delivered 9 flight motors to KSC on schedule. All test flights were successful. All spent SRMs were recovered. Design, development, manufacture, and delivery of required transportation, handling, and checkout equipment to MSFC and to KSC were completed on schedule. All items of data required by DPD 400 were prepared and delivered as directed. In the system requirements and analysis area, the point of departure from Buy 1 to the operational phase was developed in significant detail with a complete set of transition documentation available. The documentation prepared during the Buy 1 program was maintained and updated where required. The following flight support activities should be continued through other production programs: as-built materials usage tracking on all flight hardware; mass properties reporting for all flight hardware until sample size is large enough to verify that the weight limit requirements were met; ballistic predictions and postflight performance assessments for all production flights; and recovered SRM hardware inspection and anomaly identification. In the safety, reliability, and quality assurance area, activities accomplished were assurance oriented in nature and specifically formulated to prevent problems and hardware failures. The flight program to date has adequately demonstrated the success of this assurance approach. The attention focused on details of design, analysis, manufacture, and inspection to assure the production of high-quality hardware has resulted in the absence of flight failures. The few anomalies which did occur were evaluated, design or manufacturing changes incorporated, and corrective actions taken to preclude recurrence.

Source record↗
NASA NTRS1993

Scientific study in solar and plasma physics relative to rocket and balloon projects

The goals of this research are to provide scientific and technical capabilities in the areas of solar and plasma physics contained in research programs and instrumentation development relative to current rocket and balloon projects; to develop flight instrumentation design, flight hardware, and flight program objectives and participate in peer reviews as appropriate; and to participate in solar-terrestrial physics modeling studies and analysis of flight data and provide theoretical investigations as required by these studies.

Wu, S. T.↗
NASA NTRS1995

Storage Information Management System (SIMS) Spaceflight Hardware Warehousing at Goddard Space Flight Center

Goddard Space Flight Center (GSFC) on site and leased warehouses contain thousands of items of ground support equipment (GSE) and flight hardware including spacecraft, scaffolding, computer racks, stands, holding fixtures, test equipment, spares, etc. The control of these warehouses, and the management, accountability, and control of the items within them, is accomplished by the Logistics Management Division. To facilitate this management and tracking effort, the Logistics and Transportation Management Branch, is developing a system to provide warehouse personnel, property owners, and managers with storage and inventory information. This paper will describe that PC-based system and address how it will improve GSFC warehouse and storage management.

Kubicko, Richard M.↗
NASA NTRS1997

Autonomous Navigation with Ground-to-Space Doppler Measurements Referenced to a Temperature-Compensated Crystal Oscillator

The National Aeronautics and Space Administration (NASA) Goddard Space Flight Center (GSFC) has spent several years developing operational Onboard Navigation Systems (ONS's) to provide real-time autonomous, high-accuracy navigation products for spacecraft using NASA's space and ground communication systems. The highly successful Tracking and Data Relay Satellite System (TDRSS) ONS (TONS) experiment on the Explorer Platform/Extreme Ultraviolet Explorer (EP/EUVE) spacecraft, launched June 7, 1992, flight-demonstrated the ONS for high-accuracy navigation using TDRSS forward- link communications services, In late 1994, the ground station ONS (GONS) experiment, using the same EP/EUVE flight hardware, flight-demonstrated the feasibility of high-accuracy autonomous navigation using ground station forward-link communication services, with an ultrastable oscillator (USO) as the frequency reference (1 part in 10(exp 10) over 24 hours). This paper provides a follow-on analysis of GONS performance to assess the navigation accuracy achievable if GONS uses the significantly less stable (5 parts in 10(exp 8) over 24 hours, compared with a specification of 1 part in 10(exp 6)) Temperature-Compensated Crystal Oscillator (TCXO), which is integral to the transponder, as a frequency reference rather than an external USO. The GONS TCXO experiment results from a 20-day period are used to project the expected performance of an operational system. The GONS processes Doppler data derived from nominally scheduled ground station forward-link communication services using a sequential estimation algorithm enhanced by a sophisticated process noise model to provide onboard orbit and frequency determination. To evaluate the navigation accuracies achievable if a TCXO were used, actual experiment data (which used the USO as the frequency reference) were corrupted with errors from real TDRSS one-way return tracking measurements taken from EP/EUVE's TCXO. Analysis of the GONS TCXO experiment performance indicates that real-time onboard position accuracies of better than 300 meters (1 sigma) are achievable with as few as two tracking contacts per day for the EP/EUVE 525-kilometer altitude, 28.5-degree inclination orbit, provided the TCXO is as stable as that in EP/EUVE's TDRSS transponder. GONS using a TCXO frequency reference provides a viable option for many upcoming spacecraft missions with moderate position accuracy requirements and an interest in reducing their operational costs with autonomous navigation.

Radomski, M. S.↗
NASA NTRS1999

Vehicle Engineering Development Activities at the Marshall Space Flight Center

New initiatives in the Space Transportation Directorate at the Marshall Space Flight Center include an emphasis on Vehicle Engineering to enhance the strong commitment to the Directorate's projects in the development of flight hardware and flight demonstrators for the advancement of space transportation technology. This emphasis can be seen in the activities of a newly formed organization in the Transportation Directorate, The Vehicle Subsystems Engineering Group. The functions and type of activities that this group works on are described. The current projects of this group are outlined including a brief description of the status and type of work that the group is performing. A summary section is included to describe future activities.

Fisher, Mark F.↗
NASA NTRS2010

Kennedy Space Center Launch and Landing Support

The presentations describes Kennedy Space Center (KSC) payload processing, facilities and capabilities, and research development and life science experience. Topics include launch site processing, payload processing, key launch site processing roles, leveraging KSC experience, Space Station Processing Facility and capabilities, Baseline Data Collection Facility, Space Life Sciences Laboratory and capabilities, research payload development, International Space Station research flight hardware, KSC flight payload history, and KSC life science expertise.

Wahlberg, Jennifer↗
NASA NTRS2019

Additive Manufacturing for Human Space Exploration

NASA’s In Space Manufacturing Initiative (ISM): The Case for ISM - Why; ISM Path to Exploration; In Space Robotic Manufacturing and Assembly (IRMA). Additive Manufacturing (AM) Development For Liquid Rocket Engine Space Flight Hardware. MSFC (Marshall Space Flight Center) Standard and Specification For Additively Manufactured Space Flight Hardware.

Additive Manufacturing Exploration↗
NASA NTRS2009

Acoustically Induced Vibration of Structures: Reverberant Vs. Direct Acoustic Testing

Large reverberant chambers have been used for several decades in the aerospace industry to test larger structures such as solar arrays and reflectors to qualify and to detect faults in the design and fabrication of spacecraft and satellites. In the past decade some companies have begun using direct near field acoustic testing, employing speakers, for qualifying larger structures. A limited test data set obtained from recent acoustic tests of the same hardware exposed to both direct and reverberant acoustic field testing has indicated some differences in the resulting structural responses. In reverberant acoustic testing, higher vibration responses were observed at lower frequencies when compared with the direct acoustic testing. In the case of direct near field acoustic testing higher vibration responses appeared to occur at higher frequencies as well. In reverberant chamber testing and direct acoustic testing, standing acoustic modes of the reverberant chamber or the speakers and spacecraft parallel surfaces can strongly couple with the fundamental structural modes of the test hardware. In this paper data from recent acoustic testing of flight hardware, that yielded evidence of acoustic standing wave coupling with structural responses, are discussed in some detail. Convincing evidence of the acoustic standing wave/structural coupling phenomenon will be discussed, citing observations from acoustic testing of a simple aluminum plate. The implications of such acoustic coupling to testing of sensitive flight hardware will be discussed. The results discussed in this paper reveal issues with over or under testing of flight hardware that could pose unanticipated structural and flight qualification issues. Therefore, it is of paramount importance to understand the structural modal coupling with standing acoustic waves that has been observed in both methods of acoustic testing. This study will assist the community to choose an appropriate testing method and test setup in the planning stages.

Reverberant acoustic field↗
NASA NTRS2003

JSC Metal Finishing Waste Minimization Methods

THe paper discusses the following: Johnson Space Center (JSC) has achieved VPP Star status and is ISO 9001 compliant. The Structural Engineering Division in the Engineering Directorate is responsible for operating the metal finishing facility at JSC. The Engineering Directorate is responsible for $71.4 million of space flight hardware design, fabrication and testing. The JSC Metal Finishing Facility processes flight hardware to support the programs in particular schedule and mission critical flight hardware. The JSC Metal Finishing Facility is operated by Rothe Joint Venture. The Facility provides following processes: anodizing, alodining, passivation, and pickling. JSC Metal Finishing Facility completely rebuilt in 1998. Total cost of $366,000. All new tanks, electrical, plumbing, and ventilation installed. Designed to meet modern safety, environmental, and quality requirements. Designed to minimize contamination and provide the highest quality finishes.

Sullivan, Erica↗