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NASA NTRS2020

2020 IEEE Paper on Psyche margin management, Draft

In January 2017, the mission concept Psyche: Journey to a Metal World was one of two concepts selected by NASA for implementation as part of the 14th Discovery mission competition. Over the course of the past year, the Psyche team has actively worked to refine and mature the technical design, culminating in a successful completion of the Project Preliminary Design review and approval to proceed to Phase C in mid-2019. Psyche is a deep space mission utilizing solar electric propulsion (SEP), consisting of SPT-140 Hall thrusters which have been successfully employed on multiple commercial spacecraft. When launched, Psyche will carry over 1000 kg of Xenon, and will represent the farthest usage of electric propulsion usage from the Sun – a distance of over 3.3 AU. The use of solar electric propulsion in deep space has resulted in challenges unique to other missions. Spacecraft designs typically balance margins across two main elements – mass and power – that are independent of one another. Utilizing a low thrust trajectory through the application of electric propulsion introduces more elements - namely flight time, missed thrust percentage and thruster duty cycle. Moreover, these elements become connected, presenting additional relationships that must be considered. This paper will present an overview of the margin management process for Psyche, and how it has evolved from the early proposal stage to its current state. It will discuss the elements that are margined, their relationship with one another, and key uncertainties that must be addressed. It discusses challenges and mitigations obtained during the refinement of the Psyche project, culminating in a new margin strategy that enables optimization across many of the system elements, and will serve as a template for future deep space SEP missions.

Hart, William↗
NASA NTRS2010

ECLSS and Thermal Systems Integration Challenges Across the Constellation Architecture

As the Constellation Program completes its initial capability Preliminary Design Review milestone for the Initial Capability phase, systems engineering of the Environmental Control and Life Support (ECLS) and Thermal Systems for the various architecture elements has progressed from the requirements to design phase. As designs have matured for the Ares, Orion, Ground Systems, and Extravehicular (EVA) System, a number of integration challenges have arisen requiring analyses and trades, resulting in changes to the design and/or requirements. This paper will address some of the key integration issues and results, including the Orion-to-Ares shared compartment venting and purging, Orion-to-EVA suit loop integration issues with the suit system, Orion-to-ISS and Orion-to-Altair intermodule ventilation, and Orion and Ground Systems impacts from post-landing environments.

Carrasquillo, Robyn↗
NASA NTRS1965

Space vacuum investigations

Inaccessible-Non Repairable- Costly: The meaning of these words is absolute in the event of a complete failure of an orbiting spacecraft. Adequate design, or rather, minimizing chance of failure, challenges all scientists and engineers. Where experience has not been developed, the risk involved in a new application must be weighed against the consequence of a design failure. In space work, the spectrum of consequence is extremely wide. It ranges from loss of scientific data on one hand, to loss of life on the other.. There is little question that knowledge of the space environment and its effects must be determined to produce reliable spacecraft. Tests to prove the design must be performed with equipment capable of simulating the effects of the environment in which the design is to operate. This does not necessarily mean that the natural environment must be duplicated. The degree of environmental simulation that should be achieved depends primarily upon the significance of the physical effects it causes. The purpose of space vacuum simulation in an environmental test program should be accurately conceived and the testing phased to obtain maximum information from the limited samples available for test. This discussion is confined to some of the factors involved in simulating the effects of space vacuum environment. This survey is by no means complete, but will touch on some of the highlights in this field: 1. A description of the environment 2. The level of simulation necessary to evaluate its effects 3. Test equipment capability 4. Experience in test 5. Experience in orbit 6. Observations & future emphasis

VACUUM EFFECT↗
NASA NTRS2010

Commercial Orbital Transportation Cargo Services Environmental Control and Life Support Integration

The International Space Station s (ISS) largest crew and cargo resupply vehicle, the Space Shuttle, will retire in 2011. To help augment ISS resupply and return capability, NASA announced a project to promote the development of Commercial Orbital Transportation Services (COTS) for the ISS in January of 2006. By December of 2008, NASA entered into space act agreements with SpaceX and Orbital Sciences Corporation for COTS development and ISS Commercial Resupply Services (CRS). The intent of CRS is to fly multiple resupply missions each year to ISS with SpaceX s Dragon vehicle providing resupply and return capabilities and Orbital Science Corporation s Cygnus vehicle providing resupply capability to ISS. The ISS program launched an integration effort to ensure that these new commercial vehicles met the requirements of the ISS vehicle and ISS program needs. The Environmental Control and Life Support System (ECLSS) requirements cover basic cargo vehicle needs including maintaining atmosphere, providing atmosphere circulation, and fire detection and suppression. The ISS-COTS integration effort brought unique challenges combining NASA s established processes and design knowledge with the commercial companies new initiatives and limited experience with human space flight. This paper will discuss the ISS ECLS COTS integration effort including challenges, successes, and lessons learned.

Duchesne, Stephanie↗
NASA NTRS2012

Cargo Commercial Orbital Transportation Services Environmental Control and Life Support Integration

The International Space Station s (ISS) largest crew and cargo resupply vehicle, the Space Shuttle, retired in 2011. To help augment ISS resupply and return capability, NASA announced a project to promote the development of Commercial Orbital Transportation Services (COTS) for the ISS in January of 2006. By December of 2008, NASA entered into space act agreements with SpaceX and Orbital Sciences Corporation for COTS development and ISS Commercial Resupply Services (CRS). The intent of CRS is to fly multiple resupply missions each year to ISS with SpaceX s Dragon vehicle providing resupply and return capabilities and Orbital Science Corporation s Cygnus vehicle providing resupply capability to ISS. The ISS program launched an integration effort to ensure that these new commercial vehicles met the requirements of the ISS vehicle and ISS program needs. The Environmental Control and Life Support System (ECLSS) requirements cover basic cargo vehicle needs including maintaining atmosphere, providing atmosphere circulation, and fire detection and suppression. The ISS-COTS integration effort brought unique challenges combining NASA s established processes and design knowledge with the commercial companies new initiatives and limited experience with human space flight. This paper will discuss the ISS ECLS COTS integration effort including challenges, successes, and lessons learned.

Duchesne, Stephanie↗
NASA NTRS2023

Remote Plant Food Production Capability X-Hab

As human space exploration expands to long-duration missions, plant production capability serves as a solution to reduce the mass of consumables necessary to support human metabolic requirements and promote positive crew psychological health. A capability to remotely grow plants for a long-duration space mission could allow crops to be produced before a crew arrives at a staged habitat and could enable plant health to be maintained through remote operation with minimal local crew support. The University of Colorado Boulder was awarded a grant in the summer of 2012 to build a system capable of remote plant production as part of the NASA and National Space Grant Foundation eXploration Habitat (X-Hab) 2013 Academic Innovation Challenge. This report is presented as a review of the Robotic Gardening System that was designed and developed to meet the requirements outlined in the challenge. Each subsystem of the Robotic Gardening System is presented in detail. Included in this report are the design methodologies used, lessons learned throughout the design and development processes, and options or ideas for continued development and future upgrades. In addition to being a review of the Robotic Gardening System and its subsystems, this document is meant to aid with the continued development of this system in conjunction with other projects, such as team member Heather Hava’s NASA Space Technology Research Fellowship (NSTRF) work, X-Hab 2013-14 Plants Anywhere: Growing Plants in Free Habitat Spaces, and Dr. Nikolaus Correll’s NASA Early Career Professionals Fellowship.

Daniel Zukowski↗
NASA NTRS2015

Design Process of Flight Vehicle Structures for a Common Bulkhead and an MPCV Spacecraft Adapter

Design and manufacturing space flight vehicle structures is a skillset that has grown considerably at NASA during that last several years. Beginning with the Ares program and followed by the Space Launch System (SLS); in‐house designs were produced for both the Upper Stage and the SLS Multipurpose crew vehicle (MPCV) spacecraft adapter. Specifically, critical design review (CDR) level analysis and flight production drawing were produced for the above mentioned hardware. In particular, the experience of this in‐house design work led to increased manufacturing infrastructure for both Marshal Space Flight Center (MSFC) and Michoud Assembly Facility (MAF), improved skillsets in both analysis and design, and hands on experience in building and testing (MSA) full scale hardware. The hardware design and development processes from initiation to CDR and finally flight; resulted in many challenges and experiences that produced valuable lessons. This paper builds on these experiences of NASA in recent years on designing and fabricating flight hardware and examines the design/development processes used, as well as the challenges and lessons learned, i.e. from the initial design, loads estimation and mass constraints to structural optimization/affordability to release of production drawing to hardware manufacturing. While there are many documented design processes which a design engineer can follow, these unique experiences can offer insight into designing hardware in current program environments and present solutions to many of the challenges experienced by the engineering team.

Aggarwal, Pravin↗
NASA NTRS1991

Selection of wires and circuit protective devices for STS Orbiter vehicle payload electrical circuits

Electrical designers of Orbiter payloads face the challenge of determining proper circuit protection/wire size parameters to satisfy Orbiter engineering and safety requirements. This document is the result of a program undertaken to review test data from all available aerospace sources and perform additional testing to eliminate extrapolation errors. The resulting compilation of data was used to develop guidelines for the selection of wire sizes and circuit protection ratings. The purpose is to provide guidance to the engineering to ensure a design which meets Orbiter standards and which should be applicable to any aerospace design.

Gaston, Darilyn M.↗
NASA NTRS2015

Design and Fabrication Development of J-2X Engine Metallic Nozzle Extension

Maximized rocket engine performance is in part derived from expanding combustion gasses through the rocket nozzle. For upper stage engines the nozzles can be quite large. On the J-2X engine, an uncooled extension of a regeneratively cooled nozzle is used to expand the combustion gasses to a targeted exit pressure which is defined by an altitude for the desired maximum performance. Creating a J-2X nozzle extension capable of surviving the loads of test and flight environments while meeting engine system performance requirements required development of new processes and facilities. Meeting the challenges of the development resulted in concurrent J-2X nozzle extension design and fabrication. This paper describes how some of the design and fabrication challenges were resolved.

Kopicz, C.↗
NASA NTRS2022

Psyche Project Implementation During the COVID Pandemic

In January 2017, “Psyche: Journey to a Metal World” was selected for implementation as part of NASA’s Discovery program. The Psyche mission will utilize electric propulsion with SPT-140 Hall thrusters to rendezvous and orbit the metal-rich asteroid (16) Psyche, in the main asteroid belt between Mars and Jupiter. The Psyche spacecraft requires no chemical propulsion and, when launched in 2022, will be the first mission to use Hall thrusters beyond lunar orbit. The Psyche spacecraft is a hybrid development with Jet Propulsion Laboratory (JPL)-provided deep-space avionics and communications equipment mounted on a high-heritage MAXAR (formerly Space Systems Loral) Solar-Electric Propulsion (SEP) Chassis, based on their 1300 series of GEO communications satellites. The spacecraft is equipped to support a suite of science instruments, as well as a demonstration of the Deep Space Optical Communications (DSOC) technology. The spacecraft has sufficient onboard resources, autonomy, redundancy, and operability to complete a 3.5-year cruise to 16 Psyche, followed by a 20-month campaign of science investigations while orbiting the asteroid.The mission’s early concept design and progress through Preliminary Design Review (PDR) has been described in previous work. The paper will cover the recent mission progress from the Critical Design Review (CDR) through the start of Spacecraft Environmental Testing, which took place during the COVID pandemic.The authors will highlight the successful remote collaboration between the major partners: ASU, JPL, MAXAR, and the Payload teams that led to the initiation of the Assembly, Test, Launch, Operations Phase (ATLO) in early March 2021. Emphasis will be placed on the effects that the COVID-19 pandemic had on the work environment over the last 16+ months, including challenges to delivery of flight hardware and test equipment. In addition to the COVID-19 challenges, other significant anomalies discovered during design and test will be described along with any impacts to the overall science capability of the mission.

Lord, Peter↗
NASA NTRSDate not supplied

Creating Portfolio Management Concepts for Highly Agile and Innovative Government Research Programs Using Design Thinking and Lean Startup Methodologies

Managing a research and development (R&D) portfolio presents numerous challenges, such as prioritizing research areas, remaining agile, strategic workforce planning, and measuring return on investment, impact, and innovation. One government R&D program is charged with producing a high degree of innovative, transformational breakthroughs in aviation technology. A practical, structured methodology for strategically prioritizing emerging aviation R&D in such an environment is lacking. The existing multi-criteria decision aid tools are primarily utilized at an enterprise level, take months to set up and collect data, require large teams of experts, are used on an infrequent basis, and are not conducive to a highly innovative, high-risk portfolio. Prior to audaciously creating a new portfolio prioritization process, the exact challenges with portfolio management for R&D projects were identified using the design thinking and lean start-up methods. A key part of this discovery process was interviewing stakeholders, as well as other managers of organizations charged with producing innovative portfolios. These interviews, as well as additional techniques, were used to develop a deeper understanding of the challenges and, subsequently, lay the foundation for development of an effective portfolio prioritization process. Four potential concepts that represent key findings emerged: carefully selected criteria for portfolio assessment and selection, targeted portfolio turnover rate, dynamic portfolio prioritization framework, and streamlined transition or commercialization of R&D. Acting on any one of the resulting portfolio management concepts will increase the transparency and confidence in portfolio decisions and, ideally, result in a greater degree of transformational breakthroughs in aviation technology.

project portfolio management↗
NASA NTRS2017

Advanced Deployable Shell-Based Composite Booms for Small Satellite Structural Applications Including Solar Sails

State of the art deployable structures are mainly being designed for medium to large size satellites. The lack of reliable deployable structural systems for low cost, small volume, rideshare-class spacecraft severely constrains the potential for using small satellite platforms for affordable deep space science and exploration precursor missions that could be realized with solar sails. There is thus a need for reliable, lightweight, high packaging efficiency deployable booms that can serve as the supporting structure for a wide range of small satellite systems including solar sails for propulsion. The National Air and Space Administration (NASA) is currently investing in the development of a new class of advanced deployable shell-based composite booms to support future deep space small satellite missions using solar sails. The concepts are being designed to: meet the unique requirements of small satellites, maximize ground testability, permit the use of low-cost manufacturing processes that will benefit scalability, be scalable for use as elements of hierarchical structures (e.g. trusses), allow long duration storage, have high deployment reliability, and have controlled deployment behavior and predictable deployed dynamics. This paper will present the various rollable boom concepts that are being developed for 5-20 m class size deployable structures that include solar sails with the so-called High Strain Composites (HSC) materials. The deployable composite booms to be presented are being developed to expand the portfolio of available rollable booms for small satellites and maximize their length for a given packaged volume. Given that solar sails are a great example of volume and mass optimization, the booms were designed to comply with nominal solar sail system requirements for 6U CubeSats, which are a good compromise between those of smaller form factors (1U, 2U and 3U CubeSats) and larger ones (12 U and 27 U future CubeSats, and ESPA-class microsatellites). Solar sail missions for such composite boom systems are already under consideration and development at NASA, as well as mission studies that will benefit from planned scaled-up versions of the composite boom technologies to be introduced. The paper presents ongoing research and development of thin-shell rollable composite booms designed under the particular stringent and challenging system requirements of relatively large solar sails housed on small satellites. These requirements will be derived and listed. Several new boom concepts are proposed and other existing ones are improved upon using thin-ply composite materials to yield unprecedented compact deployable structures. Some of these booms are shown in Fig. 1. For every boom to be introduced the scalable fabrication process developed to keep the overall boom system cost down will be shown. Finally, the initial results of purposely designed boom structural characterization test methods with gravity off-loading will be presented to compare their structural performance under expected and general load cases.

Fernandez, Juan M.↗
NASA NTRS1994

Human factors involvement in bringing the power of AI to a heterogeneous user population

The Human Factors involvement in developing COMPAQ QuickSolve, an electronic problem-solving and information system for Compaq's line of networked printers, is described. Empowering customers with expert system technology so they could solve advanced networked printer problems on their own was a major goal in designing this system. This process would minimize customer down-time, reduce the number of phone calls to the Compaq Customer Support Center, improve customer satisfaction, and, most importantly, differentiate Compaq printers in the marketplace by providing the best, and most technologically advanced, customer support. This represents a re-engineering of Compaq's customer support strategy and implementation. In its first generation system, SMART, the objective was to provide expert knowledge to Compaq's help desk operation to more quickly and correctly answer customer questions and problems. QuickSolve is a second generation system in that customer support is put directly in the hands of the consumers. As a result, the design of QuickSolve presented a number of challenging issues. Because the produce would be used by a diverse and heterogeneous set of users, a significant amount of human factors research and analysis was required while designing and implementing the system. Research that shaped the organization and design of the expert system component as well.

Czerwinski, Mary↗
NASA NTRS1974

Apollo experience report: Thermal protection subsystem

The Apollo command module was the first manned spacecraft to be designed to enter the atmosphere of the earth at lunar-return velocity, and the design of the thermal protection subsystem for the resulting entry environment presented a major technological challenge. Brief descriptions of the Apollo command module thermal design requirements and thermal protection configuration, and some highlights of the ground and flight testing used for design verification of the system are presented. Some of the significant events that occurred and decisions that were made during the program concerning the thermal protection subsystem are discussed.

Pavlosky, J. E.↗
NASA NTRS1991

A thermal shield concept for the Solar Probe mission

The Solar Probe spacecraft will travel to within 4 solar radii of the sun's center while performing a variety of fundamental experiments in space physics. Exposure to 2900 earth suns (400 W/sq cm) at perihelion imposes severe thermal and material demands on a solar shield system designed to protect the payload that will reside within the shield's shadow envelope or umbra. The design of the shield subsystem is a thermal/materials challenge requiring new technology development. While currently in the preproject study phase, anticipating a 1995 project start, shield preliminary design efforts are currently underway. This paper documents the current status of the mission concept, the materials issues, the configuration concept for the shield subsystem, the current configuration studies performed to date, and the required material testing to provide a database to support a design effort required to develop the shield subsystem.

Miyake, Robert N.↗
NASA NTRSDate not supplied

Recent Advances in the U.S. in Ablative TPS for In-situ Exploration of Giant Planets

The Decadal Survey report released [1] prioritizes Uranus as the highest priority Flagship class mission to be explored with an orbiter and a probe and it also recommended Saturn Probe under New Frontiers mission class. Thermal protection system (TPS) is essential for Uranus and Saturn probe missions. The two cardinal requirements are that it must be fail-safe and yet be mass efficient. The Decadal Survey report also pointed out the readiness of heatshield for extreme entry environment technology (HEEET) at TRL 6 for probe missions at Gas Giants. HEEET relies on 3-D weaving and is shown to be a robust and mass efficient TPS through ground testing and analysis. HEEET was matured to TRL 6 in 2019. HEEET was reported at the Ice Giant Workshop in 2019 at Marseille. Since 2019, significant advances have been made primarily because of Mars Sample Return (MSR) mission. MSR baselined 3-D Woven TPS as its heatshield for the earth entry system. MSR earth entry system (EES) requirements and the resulting heatshield/TPS requirements are most stringent of all entry missions. This is a result of backward contamination protection which classifies MSR as a “restricted class 5” mission to safeguard the accidental release of potentially hazardous Mars Sample into Earth’s atmosphere. Complex requirements for the heatshield start with micro-meteor impact tolerance followed by the requirement for steep entry to minimize the size of the impact footprint which results in extreme heating. The heatshield is part of the impact attenuation system. The EES architecture does not use a parachute and is designed to tolerate impact loads. Hence heatshield TPS selection and design becomes one of the key challenges. After completion of the HEEET technology maturation in 2019, IRAD efforts focused on assessing the 3-D Woven family of TPS to MSR EES. After nearly two years of evaluation of alternate TPS such as carbon phenolic, C-C hot structure, PICA, and 3-D woven family of TPS, a single layer 3-D woven TPS derived from the dual-layer HEEET was down selected and is currently the baseline. A new loom capable of weaving the single-layer 3-D woven preform at 80” wide has been designed, assembled and is currently on the verge of weaving the MSR EES TPS. During the HEEET maturation and the follow-on development, the single-layer TPS has been tested at extreme heating conditions. As a result, single layer TPS was recommended and evaluated during the Planetary Mission Concept Studies funded by NASA in preparation for the Decadal committee. In addition, in anticipation of Saturn mission proposals, single layer was evaluated as well. Aerocapture can reduce the trip time, also allow bigger payload fraction and in addition, it allows for the possibility of probe delivery once the spacecraft is in orbit. This can lead to obtaining both in-situ data as well as data from orbit simultaneously. Since Aerocapture depletes energy/velocity, probe delivery from orbit reduces the demand on TPS. Aerocapture was mentioned in the Decadal Study report as ready for implementation, but due to perceived risk it is not adopted by the mission designers. Establishing TPS readiness for aerocapture missions will be addressed. Going one step beyond aerocapture is aerogravity assist if fast return is the goal. Recent studies [4] looked at aerogravity assist and the TPS readiness. This talk will highlight both aerocapture and aerogravity assist from a TPS perspective. The main objective of this proposed talk is to present a comprehensive picture of the SOA TPS technology including recent developments. The talk will highlight advances in manufacturing, results from the Decadal White Papers, PMCS and other studies, and aerocapture and aerogravity assist that could play a role in the near or far term in-situ exploration.

E. Venkatapathy↗
NASA NTRS2006

HSR Overview

The leading Aeronautics program within NASA is the High Speed Research Program (HSR). The HSR program's highest priorities are high pay-off technologies for airframe and propulsion systems required for a high speed civil transport (HSCT). These priorities have been developed collaboratively with NASA, FAA and the US Industry (Boeing-McDonnell Douglas, Pratt & Whitney and General Electric). Phase one of the HSR program started on 1990, and concentrated on the environmental challenges of minimizing NOx and noise. The first program goal is to reduce the NOx emission index to less than 5 (Concord NOx index is 20 and is unacceptable), in order to have little impact on the earth's ozone layer. The second goal is to reduce noise levels to FAR Stage 3 (or better), comparable to those of subsonic aircraft (far below the Concorde noise levels that require exemptions form less stringent standards). This requirement greatly impacts the nozzle design increasing its length and complexity and poses unique sealing challenges. Phase two started in 1993 and initiated work on the technologies required for an economical HSCT. Materials technologies under development include a ceramic-matrix-composite combustion liner, lightweight materials for the nozzle, as well long-life turbomachinery disk and blade alloys. Other required materials are being developed under the DOD-IHPTET program, where there is close cooperation. Economic goals translate into the development of technologies for tri-class service, 5000 nautical mile range aircraft with a ticket price no more than 20% over the subsonic ticket price. The potential market could be as large as 1500 aircraft, according to a Boeing study. Technology alone will not enable this airplane, yet without enabling technologies "on the shelf", it will not occur. The HSCT engine will be the largest engine ever built and operate at maximum conditions for long periods of time posing a number of challenges. The HSR engine mission requires that rotating equipment stay at take-off condition temperatures for hours not minutes per flight. Hence rotating equipment and seals must operate for many thousands of hours at extreme temperatures. It is anticipated that the nozzle will be 12 feet long and roughly 4 ft. by 5 ft. in cross-section with a nominal airflow of 800 lbs/sec. The complex function of the nozzle (including an ejector for noise attenuation) combined with long life place new demands on nozzle seal design. Three inlet configurations are under consideration with attendant sealing challenges, as will be illustrated herein. Four of these engines are required to propel a 5000 nautical mile class vehicle which demand that component reliability be at the highest possible level. In response, an HSR seals session was implemented as a part of the 1997-Seals and Secondary Flow Workshop. Overview presentations were given for each of the following areas: inlet, turbomachinery, combustor and nozzle. The HSCT seal issues center on durability and efficiency of rotating equipment seals (including brush seals), structural seals (including rope seals and other advanced concepts), and high-speed bearing and sump seals. Tighter clearances, propulsion system size and thermal requirements represent extremes that challenge the component designers. This document provides an initial step toward defining HSR seal needs. The overview for HSR seal designs includes, defining seal objectives, summarizing sealing and materials requirements, presenting relevant seal cross-sections, and identifying technology needs for the HSR office.

Hendricks, R. C.↗