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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Unmanned Aircraft Systems (UAS) Integration in the National Airspace System (NAS) Project KDP-C Review

The topics discussed are the UAS-NAS project life-cycle and ARMD thrust flow down, as well as the UAS environments and how we operate in those environments. NASA's Armstrong Flight Research Center at Edwards, CA, is leading a project designed to help integrate unmanned air vehicles into the world around us. The Unmanned Aircraft Systems Integration in the National Airspace System project, or UAS in the NAS, will contribute capabilities designed to reduce technical barriers related to safety and operational challenges associated with enabling routine UAS access to the NAS. The project falls under the Integrated Systems Research Program office managed at NASA Headquarters by the agency's Aeronautics Research Mission Directorate. NASA's four aeronautics research centers - Armstrong, Ames Research Center, Langley Research Center, and Glenn Research Center - are part of the technology development project. With the use and diversity of unmanned aircraft growing rapidly, new uses for these vehicles are constantly being considered. Unmanned aircraft promise new ways of increasing efficiency, reducing costs, enhancing safety and saving lives 460265main_ED10-0132-16_full.jpg Unmanned aircraft systems such as NASA's Global Hawks (above) and Predator B named Ikhana (below), along with numerous other unmanned aircraft systems large and small, are the prime focus of the UAS in the NAS effort to integrate them into the national airspace. Credits: NASA Photos 710580main_ED07-0243-37_full.jpg The UAS in the NAS project envisions performance-based routine access to all segments of the national airspace for all unmanned aircraft system classes, once all safety-related and technical barriers are overcome. The project will provide critical data to such key stakeholders and customers as the Federal Aviation Administration and RTCA Special Committee 203 (formerly the Radio Technical Commission for Aeronautics) by conducting integrated, relevant system-level tests to adequately address safety and operational challenges of national airspace access by unmanned aircraft systems, or UAS. In the process, the project will work with other key stakeholders to define necessary deliverables and products to help enable such access. Within the project, NASA is focusing on five sub-projects. These five focus areas include assurance of safe separation of unmanned aircraft from manned aircraft when flying in the national airspace; safety-critical command and control systems and radio frequencies to enable safe operation of UAS; human factors issues for ground control stations; airworthiness certification standards for UAS avionics and integrated tests and evaluation designed to determine the viability of emerging UAS technology. Five Focus Areas of the UAS Integration in the NAS Project Separation Assurance Provide an assessment of how planned Next Generation Air Transportation System (NextGen) separation assurance systems, with different functional allocations, perform for UAS in mixed operations with manned aircraft Assess the applicability to UAS and the performance of NASA NextGen separation assurance systems in flight tests with realistic latencies and uncertain trajectories Assess functional allocations ranging from today's ground-based, controller-provided aircraft separation to fully autonomous airborne self-separation Communications Develop data and rationale to obtain appropriate frequency spectrum allocations to enable safe and efficient operation of UAS in the NAS Develop and validate candidate secure safety-critical command and control system/subsystem test equipment for UAS that complies with UAS international/national frequency regulations, standards and recommended practices and minimum operational and aviation system performance standards for UAS Perform analysis to support recommendations for integration of safety-critical command and control systems and air traffic control communications to ensure safe and efficient operation of UAS in the NAS Human Systems Integration Develop a research test bed and database to provide data and proof of concept for GCS - ground control station - operations in the NAS Coordinate with standards organizations to develop human-factors guidelines for GCS operation in the NAS Certification Define a UAS classification scheme and approach to determining Federal Aviation Regulation airworthiness requirements applicable to all UAS digital avionics Provide hazard and risk-related data to support development of type design criteria and best development practices Integrated Tests and Evaluation Integrate and test mature concepts from technical elements to demonstrate and test viability Evaluate the performance of technology development in a relevant environment (full-mission, human-in-the-loop simulations and flight tests)

outreach↗
NASA NTRS2015

Numerical Modeling of Self-Pressurization and Pressure Control by Thermodynamic Vent System in a Cryogenic Tank

This paper presents a numerical model of a system-level test bed - the multipurpose hydrogen test bed (MHTB) using Generalized Fluid System Simulation Program (GFSSP). MHTB is representative in size and shape of a fully integrated space transportation vehicle liquid hydrogen (LH2) propellant tank and was tested at Marshall Space Flight Center (MSFC) to generate data for cryogenic storage. GFSSP is a finite volume based network flow analysis software developed at MSFC and used for thermo-fluid analysis of propulsion systems. GFSSP has been used to model the self-pressurization and ullage pressure control by Thermodynamic Vent System (TVS). A TVS typically includes a Joule-Thompson (J-T) expansion device, a two-phase heat exchanger, and a mixing pump and spray to extract thermal energy from the tank without significant loss of liquid propellant. Two GFSSP models (Self-Pressurization & TVS) were separately developed and tested and then integrated to simulate the entire system. Self-Pressurization model consists of multiple ullage nodes, propellant node and solid nodes; it computes the heat transfer through Multi-Layer Insulation blankets and calculates heat and mass transfer between ullage and liquid propellant and ullage and tank wall. TVS model calculates the flow through J-T valve, heat exchanger and spray and vent systems. Two models are integrated by exchanging data through User Subroutines of both models. The integrated models results have been compared with MHTB test data of 50% fill level. Satisfactory comparison was observed between test and numerical predictions.

Majumdar, Alok↗
NASA NTRS2017

Vehicle-Level Oxygen/Methane Propulsion System Hotfire Testing at Thermal Vacuum Conditions

A prototype integrated liquid oxygen/liquid methane propulsion system was hot-fire tested at a variety of simulated altitude and thermal conditions in the NASA Glenn Research Center Plum Brook Station In-Space Propulsion Thermal Vacuum Chamber (formerly B2). This test campaign served two purposes: 1) Characterize the performance of the Plum Brook facility in vacuum accumulator mode and 2) Collect the unique data set of an integrated LOX/Methane propulsion system operating in high altitude and thermal vacuum environments (a first). Data from this propulsion system prototype could inform the design of future spacecraft in-space propulsion systems, including landers. The test vehicle for this campaign was the Integrated Cryogenic Propulsion Test Article (ICPTA), which was constructed for this project using assets from the former Morpheus Project rebuilt and outfitted with additional new hardware. The ICPTA utilizes one 2,800 lbf main engine, two 28 lbf and two 7 lbf reaction control engines mounted in two pods, four 48-inch propellant tanks (two each for liquid oxygen and liquid methane), and a cold helium system for propellant tank pressurization. Several hundred sensors on the ICPTA and many more in the test cell collected data to characterize the operation of the vehicle and facility. Multiple notable experiments were performed during this test campaign, many for the first time, including pressure-fed cryogenic reaction control system characterization over a wide range of conditions, coil-on-plug ignition system demonstration at the vehicle level, integrated main engine/RCS operation, and a non-intrusive propellant mass gauging system. The test data includes water-hammer and thermal heat leak data critical to validating models for use in future vehicle design activities. This successful test campaign demonstrated the performance of the updated Plum Brook In-Space Propulsion thermal vacuum chamber and incrementally advanced the state of LOX/Methane propulsion technology through numerous system-level and subsystem experiments.

Morehead, Robert L.↗
NASA NTRS2019

Recent Advancements in Modeling and Simulation of Entry Systems at NASA

This paper describes recent development of modeling and simulation technologies for entry systems in support of NASA's exploration missions. Mission-tailored research and development in modeling of entry systems occurs across the Agency (e.g., within the Orion and Mars 2020 Programs), however the aim of this paper is to discuss the broad, cross-mission research conducted by NASA's Entry Systems Modeling (ESM) Project, which serves as the Agency's only concerted effort toward advancing entry systems across a range of technical disciplines. Technology development in ESM is organized and prioritized from a system-level perspective, resulting in four broad technical areas of investment: (1) Predictive material modeling, (2) Shock layer kinetics and radiation, (3) Computational and experimental aerosciences, and (4) Guidance, navigation, and control. Investments in thermal protection material modeling are geared toward high-fidelity, predictive models capable of handling complex structures, with an eye toward optimizing design performance and quantifying thermal protection system reliability. New computational tools have been developed to characterize material properties and behavior at the microstructural level, and experimental techniques (molecular beam scattering, micro-computed tomography, among others) have been developed to measure material kinetics, morphology, and other parameters needed to inform and validate detailed simulations. Advancements have also been made in macrostructural simulation capability to enable 3-D system-scale calculations of material response with complex topological features, including differential recession of tile gaps. Research and development in the area of shock layer kinetics has focused on air and CO2-based atmospheres. Capacity and capability of the NASA Ames Electric Arc Shock Tube (EAST) have been expanded in recent years and analysis of resulting data has led to several improvements in kinetic models, while simultaneously reducing uncertainties associated with radiative heat transfer predictions. First-principles calculations of fundamental kinetic, thermodynamic, and transport data, along with state-specific models for non-equilibrium flow regimes, have also yielded new insights and have the potential to vastly improve model fidelity. Aerosciences is a very broad area of interest in entry systems, yet a number of important challenges are being addressed: Coupled fluid-structure simulations of parachute inflation and dynamics; Experimental and computational studies of vehicle dynamics; Multi-phase flow with dust particles to simulate entry environments at Mars during dust storms; Studies of roughness-induced heating augmentation relevant to tiled and woven thermal protection systems; and Advanced numerical methods to optimize computational analyses for desired accuracy versus cost. Guidance and control in the context of entry systems has focused on development of methods for multi-axis control (i.e. pitch and yaw, rather than bank angle alone) of spacecraft during entry and descent. With precision landing requirements driven by Mars human exploration goals, recent efforts have yielded 6-DOF models of multi-axis control with propulsive descent of both inflatable and rigid ellipsled-like architectures.

Barnhardt, Michael D.↗
NASA NTRS2014

The X-15 3-65 Accident: An Aircraft Systems and Flight Control Perspective

Despite the NASA X-15 program's outstanding success in developing and operating the first manned hypersonic research platform, the program suffered a fatal accident on November 15, 1967, when X-15-3, the only aircraft outfitted with advanced pilot displays and an adaptive flight control system, was lost after entering uncontrolled flight at an altitude of 230,000 feet and a velocity near Mach 5. The pilot, Major Michael J. Adams, was incapacitated by the aircraft accelerations and was killed either during the ensuing breakup or upon ground impact. In light of mitigating risk to current and emerging manned aerospace vehicles, a comprehensive systems level analysis of the accident is presented with a focus on the electrical power, flight control, and instrumentation failures that affected not only the vehicle dynamics but substantially impacted the pilot decisions that led to an inevitable loss of control. Insights based on reconstructed flight data as well as analysis and simulation of the X-15's unique adaptive control system, yield new conclusions about the reasons for the control systems anomalous behavior and the system-level interactions and human-machine interface design oversights that led to the accident.

Accident Investigation↗
NASA NTRS2016

A Model Based Systems Engineering Approach Towards Developing a Rapid Analysis and Trades Environment

In this work, an integrated and end-to-end modeling environment was developed to assess the system-level impacts of evolving requirements and design parameters. Researchers at the Georgia Institute of Technology's Aerospace Systems Design Laboratory (ASDL) collaborated with JPL engineers to develop, implement, and test a modeling environment to assess design changes to a notional Europa Mission called the Jupiter Europa Buzzer (JEB). This environment was developed using a Model-Based Systems Engineering (MBSE) approach and consists of three major components: the Systems Model, the Mission Simulator, and the Web Based Interactive Dashboard. In summary, utilizing this environment in a representative notional end-to-end scenario, performance margins were calculated in hours while maintaining consistent analytical, hardware, and operational assumptions.

Model Based System Engineering↗
NASA NTRS2019

Technology Development and Infusion by NASA's Entry Systems Modeling Project

This paper describes recent development of modeling and simulation technologies for entry systems and their infusion into NASA's exploration missions. Technology development is organized and prioritized using a system-level perspective, resulting in four broad technical areas of investment: (1) Thermal protection material modeling, (2) Shock layer kinetics and radiation, (3) Computational and experimental aerosciences, and (4) Guidance, navigation, and control. The paper will highlight key contributions from each of these areas, their impacts from a spacecraft and mission design perspective, and discuss planned future investment. Aspects of each technical area are only briefly summarized here. Thermal protection material modeling is geared toward high-fidelity, predictive models capable of optimizing design performance, post-flight reconstruction, and quantifying thermal protection system reliability. New computational tools and experimental techniques have been applied to Orion, MSL/Mars 2020, Mars InSight, and Mars Sample Return missions. Research and development in the area of shock layer kinetics has focused on air and CO2-based atmospheres. In both cases, substantial improvements in model uncertainty have directly impacted the development of mission margin policies, flight instrumentation design and analysis (Orion and Mars 2020), and have even revealed the importance of neglected phenomena like mid-wave infrared radiation of CO2. Aerosciences is a very broad area of interest in entry systems, yet a number of important challenges are being addressed: Coupled fluid-structure simulations of parachute inflation and dynamics affecting Orion, Commercial Crew, and Mars programs; Experimental and computational studies of vehicle dynamics; Multi-phase flow with dust particles to simulate augmentation of aerothermal environments at Mars during dust storms; and studies of roughness-induced heating augmentation relevant to tiled (Orion, Mars 2020) and woven (Mars Sample Return) thermal protection systems. Guidance and control in the context of entry systems has focused on development of methods for multi-axis control (i.e. pitch and yaw, rather than bank angle alone) of spacecraft during entry and descent, with precision landing requirements driven by Mars human exploration goals.

Barnhardt, Michael D.↗
NASA NTRS2014

MARGInS: Model-Based Analysis of Realizable Goals in Systems

Under NASAs Constellation effort, the Exploration Technology Development Program funded research toward a system validation capability that applied machine learning and test-case generation techniques to the analysis of black-box system behavior. The behavior analysis capability scaled to spaces of hundreds of input parameters and tens of thousands of test cases. Aerospace systems at the vehicle level, especially those systems which contain some level of autonomy, are best described by hybrid and non-linear mathematics. Even simplified models of such systems need parameter dimensionalities in the hundreds or thousands of parameters in order to capture sufficient fidelity. The System Safety Assessments (such as those described in the SAE ARP 4761A Safety Assessment Process guidelines) for these systems are prone to errorinteractions between the vehicles subsystems are complex, and can display emergent behaviors. NASA captured this new analysis in the Model-based Analysis of Realizable Goals in Systems (MARGInS) tool and applied it to the Pad Abort 1 (PA-1) simulation as part of the independent validation and verification cycle before the PA-1 flight test in May of 2010. MARGInS evaluated the adherence of the high-fidelity simulation to its requirements, and deter- mined the margins to failure from the expected nominal input conditions. Following the PA-1 test, the capabilities within the MARGInS framework have been extended with sophisticated statistical and white-box test case generation techniques and applied to other NASA missions. The frame- work now includes a critical factors analysis that was applied to NASAs Orion simulation and design. NASAs Aeronautics Research Mission Directorate (ARMD) leveraged the existing MARGInS framework for work on aviation safety for civil transport vehicles and for research on autonomy issues. The NASA ARMD effort created a time series output prediction capability that has been used to characterize trajectories for a plane with an adaptive control system, and a safety boundary detection capability that has been applied to an air traffic control concept of operation for the Federal Aviation Administration. The statistical and machine- learning based techniques within MARGInS have been successfully combined with concolic execution to improve the coverage of a critical unit by driving system-level inputs. The use case driving the concolic execution and MARGInS integration was inspired by the Air France 447 disaster in which the loss of a critical functionality (the airspeed calculation from the pitot tubes) led to loss of the entire plane with the people aboard. To illustrate capabilities and limitations, we will highlight the analyses for the applications listed above. We will then discuss the future plans for MARGInS and its interfaces with other tools.

Validation↗
NASA NTRS2019

Technology Development and Infusion by NASA's Entry Systems Modeling Project

This presentation describes recent development of modeling and simulation technologies by NASA's Entry Systems Modeling Project and their infusion into the Agency's exploration missions. Technology development is organized and prioritized using a system-level perspective, resulting in four broad technical areas of investment: (1) Thermal protection material modeling, (2) Shock layer kinetics and radiation, (3) Computational and experimental aerosciences, and (4) Guidance, navigation, and control. The presentation will illustrate how applied research can meaningfully impact flight programs by highlighting a few recent contributions: Orion and Mars 2020 radiative heating margin policy; Study of radiative heating at Titan; Aerothermal-mechanical erosion due to dust at Mars; Modeling the PICA-NuSil system; and contributions to modeling of parachutes for entry systems.

Barnhardt, Michael D.↗
NASA NTRS2020

Guidance and Navigation Challenges for a Mars Ascent Vehicle

This work presents studies and analysis in support of a Mars Ascent Vehicle as part of a Martian Sample Return campaign. The vehicle design has been ongoing, with rapid development of a 6 Degree of Freedom simulation to capture full vehicle dispersions and integrated performance of vehicle, guidance, navigation and control. The maturation of this simulation is presented to provide an overview of its capabilities added over the past year of effort. The results describe in detail guidance algorithm development to increase the system’s robustness to thrust sensitivities. Navigation performance and sensitivity analysis are included to describe the capabilities of the current design as well as identify primary drivers of insertion performance. Lastly, integrated vehicle 6DOF statistical results are presented to provide insight into the nominal performance of the current vehicle and insight into system-level drivers. Future work is described to outline the continuing maturation and development of the MSR MAV ascent vehicle.

Anzalone, Evan↗
NASA NTRS2018

Flight-Test Evaluation of Airframe Noise Mitigation Technologies

A series of flight tests targeting airframe noise reduction was planned and executed under the NASA Flight Demonstrations and Capabilities project. The objectives of the tests were two-fold: to evaluate the aeroacoustic performance of several noise reduction technologies in a relevant environment and to generate a comprehensive database for advancing the state of the art in simulation-based airframe noise prediction methodologies. These technologies – an Adaptive Compliant Trailing Edge flap, main landing gear fairings, and gear cavity treatments – were integrated on a NASA Gulfstream G-III aircraft to determine their effectiveness, both on a component-level (individually) and a system-level (combined) basis. With the aircraft flying an approach pattern and the engines set at ground idle, extensive acoustic measurements were acquired using a phased microphone array system. Detailed analyses of the gathered acoustic data clearly demonstrate that significant noise reduction was achieved for the flap and main landing gear components.

Khorrami, Mehdi R.↗
NASA NTRS2020

An Electrical Modeling and Thermal Analysis Toolbox for Electrified Aircraft Propulsion Simulation

A simulation toolbox has been developed to model the electrical portions of Electrified Aircraft Propulsion (EAP) systems, including self-heating of electrical systems. Dynamic models of EAP systems often include turbomachinery, an electrical power system, and a thermal management system. These portions of the propulsion system can operate on timescales covering six orders of magnitude, which poses a challenging modeling task. Assumptions and approximations are made in an effort to capture the dynamics relevant to engine, electrical system, and thermal system interactions, while still allowing for fast simulations. These assumptions and approximations enable the electrical component models to run at the time scale of the turbomachinery, neglecting the very high frequency electrical dynamics, while demonstrating representative behavior of the end-to-end system. Thus the models execute in an acceptable time frame for what would otherwise be an extremely stiff simulation. The resulting simulations of EAP systems are appropriate for system-level control design and analysis. The objective of this paper is to present an overview of the Electrical Modeling and Thermal Analysis Toolbox (EMTAT). It will describe some of the approximations made to accommodate rapid execution, and some of the design tools that allow matching the model to component specifications. This paper will also provide some examples of EAP system modeling using EMTAT.

Mark E Bell↗
NASA NTRS2020

Electrical Modeling and Thermal Analysis Toolbox (EMTAT) User’s Guide

A simulation toolbox has been developed to model the electrical portions of Electrified Aircraft Propulsion (EAP) systems, including self-heating of electrical systems. Dynamic models of EAP systems often include turbomachinery, an electrical power system, and a thermal management system. These portions of the propulsion system can operate on timescales covering six orders of magnitude, which poses a challenging modeling task. Assumptions and approximations are made in an effort to capture the dynamics relevant to engine, electrical system, and thermal system interactions, while still allowing for fast simulations. These assumptions and approximations enable the electrical component models to run at the time scale of the turbomachinery, neglecting the very high frequency electrical dynamics, while demonstrating representative behavior of the end-to-end system. Thus the models execute in an acceptable time frame for what would otherwise be an extremely stiff simulation. The resulting simulations of EAP systems are appropriate for system-level control design and analysis. The objective of this User's Guide is to present an overview of the usage of the Electrical Modeling and Thermal Analysis Toolbox (EMTAT). It will describe some of the approximations made to accommodate rapid execution, and some of the design tools that allow matching the model to component specifications. This paper will describe the basic usage of the software toolbox, and also provide an example of EAP system modeling using EMTAT.

Mark E. Bell↗
NASA NTRS2004

Modeling the TPF interferometer

The Terrestrial Planet Finder interferometer design concepts are large and complex systems that must operate in environments that are impractical to reproduce in preflight testing. The structurally-connected design is 36 meters long - longer than all but one thermal vacuum chamber in existence. The formation flying design will be comprised of up to five separate spacecraft, each with a sunshield over 15 meters on a side, and is designed to operate with formation sizes spanning over 100 meters to very close formations. System-level verification of the performance of the designs will need to rely on analytical modeling. The effort to model the many physical aspects of the designs under study is under way*. This paper describes the program of modeling for the TPF-I concepts. The program includes a number of types of models, such as the standard stand-alone optics, thermal, and structural models, as well as an end-to-end performance model of the project system called the Observatory Simulation. Aspects of each model are discussed including the purpose, methods of implementation (software applications), and approaches to validation. Program-level considerations (such as model-to-model integration and configuration management) are also discussed. Given that there are at least seven different organizations contributing to model developments and more than twenty separate models, these are special challenges.

Henry, Curt↗
NASA NTRSDate not supplied

Performance of a Regenerative Fuel Cell System for the Lunar Surface

Regenerative fuel cells (RFCs) are an attractive energy storage solution for lunar missions as a technology capable of providing a higher specific energy (i.e., W∙h/kg) than state-of-the-art packaged Li-ion battery systems. An RFC consists of the (1 & 2) electrochemical stacks (chemical to electrical energy conversion to supply electricity to an external load, i.e. the fuel cell reaction, and electrical to chemical energy conversion of supplied electrical power to dissociate water into hydrogen and oxygen gases, i.e. water electrolysis), (3) fluidic conditioning, (4) reactant storage, (5) avionics, (6) power management and distribution (PMAD), and (7) thermal management. NASA’s Glenn Research Center has designed, assembled, and tested a breadboard RFC sys-tem capable of operating autonomously for multiple simulated lunar day/night cycles in a laboratory environment. The system is comprised of a non-flow through proton exchange membrane (PEM) fuel cell stack and a liquid-anode feed PEM electrolyzer (EZ) stack designed to electrochemically compress the reactants at balanced pressures up to 12.4 MPa (1800 psia). The fluidic conditioning, avionics, PMAD, and thermal management sub-systems are largely comprised of commercial-off-the-shelf components for this system-level development effort. The hardware is controlled by a CubeSat space processor running an operational program based on core flight architecture that can control the RFC hardware autonomously through a state machine with fault monitoring. The testing results highlighted here were completed with the system in an open-loop configuration such that reactants generated through water electrolysis were vented while gas cylinders supplied fuel cell operation. The breadboard operated autonomously, but there were five unplanned transitions to a safe state that required a manual restart after reviewing the data, determining a root cause, and implementing a solution. Four of the transitions were caused by the thermal management subsystem and the fifth was caused by a water management control issue in the EZ sub-system. The RFC system operated for over 550 hours with the final cycle being slightly abbreviated due to reasons unrelated to system performance.

Kerrigan Cain↗
NASA NTRSDate not supplied

Performance of a Regenerative Fuel Cell System for the Lunar Surface

Regenerative fuel cells (RFCs) are an attractive energy storage solution for lunar missions as a technology capable of providing a higher specific energy (i.e., W∙h/kg) than state-of-the-art packaged Li-ion battery systems. An RFC consists of the (1 & 2) electrochemical stacks (chemical to electrical energy conversion to supply electricity to an external load, i.e. the fuel cell reaction, and electrical to chemical energy conversion of supplied electrical power to dissociate water into hydrogen and oxygen gases, i.e. water electrolysis), (3) fluidic conditioning, (4) reactant storage, (5) avionics, (6) power management and distribution (PMAD), and (7) thermal management. NASA’s Glenn Research Center has designed, assembled, and tested a breadboard RFC sys-tem capable of operating autonomously for multiple simulated lunar day/night cycles in a laboratory environment. The system is comprised of a non-flow through proton exchange membrane (PEM) fuel cell stack and a liquid-anode feed PEM electrolyzer (EZ) stack designed to electrochemically compress the reactants at balanced pressures up to 12.4 MPa (1800 psia). The fluidic conditioning, avionics, PMAD, and thermal management sub-systems are largely comprised of commercial-off-the-shelf components for this system-level development effort. The hardware is controlled by a CubeSat space processor running an operational program based on core flight architecture that can control the RFC hardware autonomously through a state machine with fault monitoring. The testing results highlighted here were completed with the system in an open-loop configuration such that reactants generated through water electrolysis were vented while gas cylinders supplied fuel cell operation. The breadboard operated autonomously, but there were five unplanned transitions to a safe state that required a manual restart after reviewing the data, determining a root cause, and implementing a solution. Four of the transitions were caused by the thermal management subsystem and the fifth was caused by a water management control issue in the EZ sub-system. The RFC system operated for over 550 hours with the final cycle being slightly abbreviated due to reasons unrelated to system performance.

Kerrigan Cain↗
NASA NTRS2026

Development of the Orion Life-Support Integration Facility (OLIF)

Testing the life support hardware of a vehicle that is going to take humans beyond low-Earth orbit (LEO) in conditions similar to space is crucial. The Orion Life-Support Integration Facility (OLIF) at NASA Johnson Space Center (JSC) was designed and built to test the Orion vehicle’s hardware and software as integrated systems to provide a complete Environmental Control and Life Support System (ECLSS) system-level qualification. The existing 11 Foot human rated vacuum chamber has been adapted to accommodate and integrate various qualification and flight like components of the Orion vehicle’s Air Revitalization System (ARS), Pressure Control System (PCS), Active Thermal Control System (ATCS) and the Orion Crew Survival System Suits (OCSS). The ultimate goal was to create an analog testbed that could safely support up to four test subjects in open “shirt-sleeve” or closed suit loop configurations and simulate Orion Cabin conditions. This integrated hardware/software ARS and PCS will help identify any technical issues that should be addressed prior to the Artemis-2 mission. This paper will discuss the history of Orion ECLSS hardware development testing in the 11 Foot Chamber, the challenge of integrating flight hardware and software control systems, and the capabilities that make it a unique, world class facility for NASA. It will provide an overview of past and future testing, and the lessons learned along the way.

Peter A Masi↗