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At least 1,369 records · Page 76
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Technology Transfer Challenges: A Case Study of User-Centered Design in NASA's Systems Engineering Culture

The Upper Stage (US) section of the National Aeronautics and Space Administration's (NASA) Ares I rocket will require internal access platforms for maintenance tasks performed by humans inside the vehicle. Tasks will occur during expensive critical path operations at Kennedy Space Center (KSC) including vehicle stacking and launch preparation activities. Platforms must be translated through a small human access hatch, installed in an enclosed worksite environment, support the weight of ground operators and be removed before flight - and their design must minimize additional vehicle mass at attachment points. This paper describes the application of a user-centered conceptual design process and the unique challenges encountered within NASA's systems engineering culture focused on requirements and "heritage hardware". The NASA design team at Marshall Space Flight Center (MSFC) initiated the user-centered design process by studying heritage internal access kits and proposing new design concepts during brainstorming sessions. Simultaneously, they partnered with the Technology Transfer/Innovative Partnerships Program to research inflatable structures and dynamic scaffolding solutions that could enable ground operator access. While this creative, technology-oriented exploration was encouraged by upper management, some design stakeholders consistently opposed ideas utilizing novel, untested equipment. Subsequent collaboration with an engineering consulting firm improved the technical credibility of several options, however, there was continued resistance from team members focused on meeting system requirements with pre-certified hardware. After a six-month idea-generating phase, an intensive six-week effort produced viable design concepts that justified additional vehicle mass while optimizing the human factors of platform installation and use. Although these selected final concepts closely resemble heritage internal access platforms, challenges from the application of the user-centered process provided valuable lessons for improving future collaborative conceptual design efforts.

Quick, Jason↗
NASA NTRS2006

A Holistic Approach for Risk Management During Design

In this paper, an approach for the identification, assessment, mitigation and continuous management of risks during the process of designing a space mission is presented. This approach has been developed by observing the risk patterns that occur at the Project Design Center of the Jet Propulsion Laboratory (TeamX) which develops conceptual, concurrent design of Space Missions. TeamX develops an end-to-end conceptual design of a Space Mission in a matter of one or two weeks. As the risk chair in TeamX, the author has had the opportunity to observe the risk patterns that occur during design over the course of many design sessions. This paper introduces an abstraction and generalization of those patterns. Risk is defined as anything that can go wrong, along with its approximate likelihood and consequence. The indicators, and causes, and effects of these risks are cross cutting across the multiple levels of people and processes involved in the design, and the actual design product itself.

reliability analysis↗
NASA NTRS2004

Novel Horn Designs for Power Ultrasonics

Ultrasonic horns are used in a variety of industrial and medical applications. At JPL a rock-sampling tool based on an ultrasonic horn was developed to drill, abrade and core rock samples including hard basalts. This device is an impact device, which uses ultrasonic vibratlons that occur at the horn tip to produce a sonic resonance with the aid of a loosely connected mass. Although standard horns are found in many current industrial designs they suffer from a few key limitations when used for USDC applications. Manufacturing a horn requires turning down stock material (e.g. Titanium) from the larger outer diameter to the horn tip diameter, and this process is both time consuming and wasteful. In this paper, we present novel horn designs that are specifically designed for impact applications as the USDC. One such design addressed the excasive length that is involved with the use of the horn limiting its applications when system dimensions are constrained. For this purpose, a folded horn design was conceived that reduces the overall length of the resonator (physical length) but maintains or increases the acoustic length. Initial experiments with horns having such P design indicate that the tip displacement can be further adjusted by phasing the bending displacements and the extensional displacements. Another conceived horn design is the 'dog bone' horn that uses an end mass on the horn tip io increase the impact efficiency of the horn. In this paper, the experimental results for these novel born designs are presented and compared to the results predicted by theory.

acutators↗
NASA NTRS2010

Effects of Buckling Knockdown Factor, Internal Pressure and Material on the Design of Stiffened Cylinders

A design study was conducted to investigate the effect shell buckling knockdown factor (SBKF), internal pressure and aluminum alloy material selection on the structural weight of stiffened cylindrical shells. Two structural optimization codes were used for the design study to determine the optimum minimum-weight design for a series of design cases, and included an in-house developed genetic algorithm (GA) code and PANDA2. Each design case specified a unique set of geometry, material, knockdown factor combinations and loads. The resulting designs were examined and compared to determine the effects of SBKF, internal pressure and material selection on the acreage design weight and controlling failure mode. This design study shows that use of less conservative SBKF values, including internal pressure, and proper selection of material alloy can result in significant weight savings for stiffened cylinders. In particular, buckling-critical cylinders with integrally machined stiffener construction can benefit from the use of thicker plate material that enables taller stiffeners, even when the stiffness, strength and density properties of these materials appear to be inferior.

Lovejoy, Andrew E.↗
NASA NTRS2010

Constellation Program Design Challenges as Opportunities for Educational Outreach- Lessons Learned

The Texas Space Grant Consortium (TSGC) and the NASA Exploration Systems Mission Directorate (ESMD) Education Office both have programs that present design challenges for university senior design classes that offer great opportunities for educational outreach and workforce development. These design challenges have been identified by NASA engineers and scientists as actual design problems faced by the Constellation Program in its exploration missions and architecture. Student teams formed in their senior design class select and then work on a design challenge for one or two semesters. The senior design class follows the requirements set by their university, but it must also comply with the Accreditation Board for Engineering and Technology (ABET) in order to meet the class academic requirements. Based on a one year fellowship at a TSGC university under the NASA Administrator's Fellowship Program (NAFP) and several years of experience, lessons learned are presented on the NASA Design Challenge Program.

Trevino, Robert C.↗
NASA NTRS2001

Team Expo: A State-of-the-Art JSC Advanced Design Team

In concert with the NASA-wide Intelligent Synthesis Environment Program, the Exploration Office at the Johnson Space Center has assembled an Advanced Design Team. The purpose of this team is two-fold. The first is to identify, use, and develop software applications, tools, and design processes that streamline and enhance a collaborative engineering environment. The second is to use this collaborative engineering environment to produce conceptual, system-level-of-detail designs in a relatively short turnaround time, using a standing team of systems and integration experts. This includes running rapid trade studies on varying mission architectures, as well as producing vehicle and/or subsystem designs. The standing core team is made up of experts from all of the relevant engineering divisions (e.g. Power, Thermal, Structures, etc.) as well as representatives from Risk and Safety, Mission Operations, and Crew Life Sciences among others. The Team works together during 2- hour sessions in the same specially enhanced room to ensure real-time integration/identification of cross-disciplinary issues and solutions. All subsystem designs are collectively reviewed and approved during these same sessions. In addition there is an Information sub-team that captures and formats all data and makes it accessible for use by the following day. The result is Team Expo: an Advanced Design Team that is leading the change from a philosophy of "over the fence" design to one of collaborative engineering that pushes the envelope to achieve the next-generation analysis and design environment.

Tripathi, Abhishek↗
NASA NTRS2010

Excavator Design Validation

The Excavator Design Validation tool verifies excavator designs by automatically generating control systems and modeling their performance in an accurate simulation of their expected environment. Part of this software design includes interfacing with human operations that can be included in simulation-based studies and validation. This is essential for assessing productivity, versatility, and reliability. This software combines automatic control system generation from CAD (computer-aided design) models, rapid validation of complex mechanism designs, and detailed models of the environment including soil, dust, temperature, remote supervision, and communication latency to create a system of high value. Unique algorithms have been created for controlling and simulating complex robotic mechanisms automatically from just a CAD description. These algorithms are implemented as a commercial cross-platform C++ software toolkit that is configurable using the Extensible Markup Language (XML). The algorithms work with virtually any mobile robotic mechanisms using module descriptions that adhere to the XML standard. In addition, high-fidelity, real-time physics-based simulation algorithms have also been developed that include models of internal forces and the forces produced when a mechanism interacts with the outside world. This capability is combined with an innovative organization for simulation algorithms, new regolith simulation methods, and a unique control and study architecture to make powerful tools with the potential to transform the way NASA verifies and compares excavator designs. Energid's Actin software has been leveraged for this design validation. The architecture includes parametric and Monte Carlo studies tailored for validation of excavator designs and their control by remote human operators. It also includes the ability to interface with third-party software and human-input devices. Two types of simulation models have been adapted: high-fidelity discrete element models and fast analytical models. By using the first to establish parameters for the second, a system has been created that can be executed in real time, or faster than real time, on a desktop PC. This allows Monte Carlo simulations to be performed on a computer platform available to all researchers, and it allows human interaction to be included in a real-time simulation process. Metrics on excavator performance are established that work with the simulation architecture. Both static and dynamic metrics are included.

Pholsiri, Chalongrath↗
NASA NTRS2010

Ares I Flight Control System Design

The Ares I launch vehicle represents a challenging flex-body structural environment for flight control system design. This paper presents a design methodology for employing numerical optimization to develop the Ares I flight control system. The design objectives include attitude tracking accuracy and robust stability with respect to rigid body dynamics, propellant slosh, and flex. Under the assumption that the Ares I time-varying dynamics and control system can be frozen over a short period of time, the flight controllers are designed to stabilize all selected frozen-time launch control systems in the presence of parametric uncertainty. Flex filters in the flight control system are designed to minimize the flex components in the error signals before they are sent to the attitude controller. To ensure adequate response to guidance command, step response specifications are introduced as constraints in the optimization problem. Imposing these constraints minimizes performance degradation caused by the addition of the flex filters. The first stage bending filter design achieves stability by adding lag to the first structural frequency to phase stabilize the first flex mode while gain stabilizing the higher modes. The upper stage bending filter design gain stabilizes all the flex bending modes. The flight control system designs provided here have been demonstrated to provide stable first and second stage control systems in both Draper Ares Stability Analysis Tool (ASAT) and the MSFC 6DOF nonlinear time domain simulation.

Jang, Jiann-Woei↗
NASA NTRS2010

Maximizing Launch Vehicle and Payload Design Via Early Communications

The United States? current fleet of launch vehicles is largely derived from decades-old designs originally made for payloads that no longer exist. They were built primarily for national security or human exploration missions. Today that fleet can be divided roughly into small-, medium-, and large-payload classes based on mass and volume capability. But no vehicle in the U.S. fleet is designed to accommodate modern payloads. It is usually the payloads that must accommodate the capabilities of the launch vehicles. This is perhaps most true of science payloads. It was this paradigm that the organizers of two weekend workshops in 2008 at NASA's Ames Research Center sought to alter. The workshops brought together designers of NASA's Ares V cargo launch vehicle (CLV) with scientists and payload designers in the astronomy and planetary sciences communities. Ares V was still in a pre-concept development phase as part of NASA?s Constellation Program for exploration beyond low Earth orbit (LEO). The space science community was early in a Decadal Survey that would determine future priorities for research areas, observations, and notional missions to make those observations. The primary purpose of the meetings in April and August of 2008, including the novel format, was to bring vehicle designers together with space scientists to discuss the feasibility of using a heavy lift capability to launch large observatories and explore the Solar System. A key question put to the science community was whether this heavy lift capability enabled or enhanced breakthrough science. The meetings also raised the question of whether some trade-off between mass/volume and technical complexity existed that could reduce technical and programmatic risk. By engaging the scientific community early in the vehicle design process, vehicle engineers sought to better understand potential limitations and requirements that could be added to the Ares V from the mission planning community. From the vehicle standpoint, while the human exploration mission could not be compromised to accommodate other payloads, the design might otherwise be tailored to not exclude other payload requirements. This paper summarizes the findings of the workshops and discusses the benefits of bringing together the vehicle design and science communities early in their concept phases

Morris, Bruce↗
NASA NTRS2009

Proof of Concept Study of Trade Space Configuration Tool for Spacecraft Design

Spacecraft design is a very difficult and time consuming process because requirements and criteria are often changed or modified as the design is refined. Accounting for these adjustments in the design constraints plays a significant role in furthering the overall progress. There are numerous aspects and variables that hold significant influence on various characteristics of the design. This can be especially frustrating when attempting to conduct rapid trade space analysis on system configurations. Currently, the data and designs considered for trade space evaluations can only be displayed by using the traditional interfaces of Excel spreadsheets or CAD (Computer Aided Design) models. While helpful, these methods of analyzing the data from a systems engineering approach can be rather complicated and overwhelming. As a result, a proof of concept was conducted on a dynamic data visualization software called Thinkmap SDK (Software Developer Kit) to allow for better organization and understanding of the relationships between the various aspects that make up an entire design. The Orion Crew Module Aft Bay Subsystem was used as the test case for this study because the design and layout of many of the subsystem components will be significant in ensuring the overall center of gravity of the capsule is correct. A simplified model of this subsystem was created and programmed using Thinkmap SDK to create a preliminary prototype application of a Trade Space Configuration Tool. The completed application ensures that the core requirements for the Tool can be met. Further development is strongly suggested to produce a full prototype application to allow final evaluations and recommendations of the software capabilities.

Glidden, Geoffrey L.↗
NASA NTRS2011

Design and Test of Advanced Thermal Simulators for an Alkali Metal-Cooled Reactor Simulator

The Early Flight Fission Test Facility (EFF-TF) at NASA Marshall Space Flight Center (MSFC) has as one of its primary missions the development and testing of fission reactor simulators for space applications. A key component in these simulated reactors is the thermal simulator, designed to closely mimic the form and function of a nuclear fuel pin using electric heating. Continuing effort has been made to design simple, robust, inexpensive thermal simulators that closely match the steady-state and transient performance of a nuclear fuel pin. A series of these simulators have been designed, developed, fabricated and tested individually and in a number of simulated reactor systems at the EFF-TF. The purpose of the thermal simulators developed under the Fission Surface Power (FSP) task is to ensure that non-nuclear testing can be performed at sufficiently high fidelity to allow a cost-effective qualification and acceptance strategy to be used. Prototype thermal simulator design is founded on the baseline Fission Surface Power reactor design. Recent efforts have been focused on the design, fabrication and test of a prototype thermal simulator appropriate for use in the Technology Demonstration Unit (TDU). While designing the thermal simulators described in this paper, effort were made to improve the axial power profile matching of the thermal simulators. Simultaneously, a search was conducted for graphite materials with higher resistivities than had been employed in the past. The combination of these two efforts resulted in the creation of thermal simulators with power capacities of 2300-3300 W per unit. Six of these elements were installed in a simulated core and tested in the alkali metal-cooled Fission Surface Power Primary Test Circuit (FSP-PTC) at a variety of liquid metal flow rates and temperatures. This paper documents the design of the thermal simulators, test program, and test results.

Garber, Anne E.↗
NASA NTRS2011

Inverse Design of Low-Boom Supersonic Concepts Using Reversed Equivalent-Area Targets

A promising path for developing a low-boom configuration is a multifidelity approach that (1) starts from a low-fidelity low-boom design, (2) refines the low-fidelity design with computational fluid dynamics (CFD) equivalent-area (Ae) analysis, and (3) improves the design with sonic-boom analysis by using CFD off-body pressure distributions. The focus of this paper is on the third step of this approach, in which the design is improved with sonic-boom analysis through the use of CFD calculations. A new inverse design process for off-body pressure tailoring is formulated and demonstrated with a low-boom supersonic configuration that was developed by using the mixed-fidelity design method with CFD Ae analysis. The new inverse design process uses the reverse propagation of the pressure distribution (dp/p) from a mid-field location to a near-field location, converts the near-field dp/p into an equivalent-area distribution, generates a low-boom target for the reversed equivalent area (Ae,r) of the configuration, and modifies the configuration to minimize the differences between the configuration s Ae,r and the low-boom target. The new inverse design process is used to modify a supersonic demonstrator concept for a cruise Mach number of 1.6 and a cruise weight of 30,000 lb. The modified configuration has a fully shaped ground signature that has a perceived loudness (PLdB) value of 78.5, while the original configuration has a partially shaped aft signature with a PLdB of 82.3.

Li, Wu↗
NASA NTRS2011

Shape Memory Alloy Actuator Design: CASMART Collaborative Best Practices

Upon examination of shape memory alloy (SMA) actuation designs, there are many considerations and methodologies that are common to them all. A goal of CASMART's design working group is to compile the collective experiences of CASMART's member organizations into a single medium that engineers can then use to make the best decisions regarding SMA system design. In this paper, a review of recent work toward this goal is presented, spanning a wide range of design aspects including evaluation, properties, testing, modeling, alloy selection, fabrication, actuator processing, design optimization, controls, and system integration. We have documented each aspect, based on our collective experiences, so that the design engineer may access the tools and information needed to successfully design and develop SMA systems. Through comparison of several case studies, it is shown that there is not an obvious single, linear route a designer can adopt to navigate the path of concept to product. SMA engineering aspects will have different priorities and emphasis for different applications.

Benafan, Othmane↗
NASA NTRS2011

Reliability Based Design for a Raked Wing Tip of an Airframe

A reliability-based optimization methodology has been developed to design the raked wing tip of the Boeing 767-400 extended range airliner made of composite and metallic materials. Design is formulated for an accepted level of risk or reliability. The design variables, weight and the constraints became functions of reliability. Uncertainties in the load, strength and the material properties, as well as the design variables, were modeled as random parameters with specified distributions, like normal, Weibull or Gumbel functions. The objective function and constraint, or a failure mode, became derived functions of the risk-level. Solution to the problem produced the optimum design with weight, variables and constraints as a function of the risk-level. Optimum weight versus reliability traced out an inverted-S shaped graph. The center of the graph corresponded to a 50 percent probability of success, or one failure in two samples. Under some assumptions, this design would be quite close to the deterministic optimum solution. The weight increased when reliability exceeded 50 percent, and decreased when the reliability was compromised. A design could be selected depending on the level of risk acceptable to a situation. The optimization process achieved up to a 20-percent reduction in weight over traditional design.

Patnaik, Surya N.↗
NASA NTRS2003

Meshed-Pumpkin Super-Pressure Balloon Design

An improved, lightweight design has been proposed for super-pressure balloons used to carry scientific instruments at high altitudes in the atmosphere of Earth for times as long as 100 days. [A super-pressure balloon is one in which the pressure of the buoyant gas (typically, helium) is kept somewhat above ambient pressure in order to maintain approximately constant density and thereby regulate the altitude.] The proposed design, called "meshed pumpkin," incorporates the basic concept of the pumpkin design, which is so named because of its appearance. The pumpkin design entails less weight than does a spherical design, and the meshed-pumpkin design would reduce weight further. The basic idea of the meshed-pumpkin design is to reinforce the membrane of a pumpkin balloon by attaching a strong, lightweight fabric mesh to its outer surface. The reinforcement would make it possible to reduce the membrane mass to one-third or less of that of the basic pumpkin design while retaining sufficient strength to enable the balloon to remain at approximately constant altitude for months.

Jones, Jack↗
NASA NTRS2013

Preliminary Design and Analysis of an In-plane PRSEUS Joint

As part of the National Aeronautics and Space Administration's (NASA's) Environmentally Responsible Aviation (ERA) program, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) has been designed, developed and tested. However, PRSEUS development efforts to date have only addressed joints required to transfer bending moments between PRSEUS panels. Development of in-plane joints for the PRSEUS concept is necessary to facilitate in-plane transfer of load from PRSEUS panels to an adjacent structure, such as from a wing panel into a fuselage. This paper presents preliminary design and analysis of an in-plane PRSEUS joint for connecting PRSEUS panels at the termination of the rod-stiffened stringers. Design requirements are provided, the PRSEUS blade joint concept is presented, and preliminary design changes and analyses are carried out to examine the feasibility of the proposed in-plane PRSEUS blade joint. The study conducted herein focuses mainly on the PRSEUS structure on one side of the joint. In particular, the design requirements for the rod shear stress and bolt bearing stress are examined. A PRSEUS blade joint design was developed that demonstrates the feasibility of this in-plane PRSEUS joint concept to terminate the rod-stiffened stringers. The presented design only demonstrates feasibility, therefore, some areas of refinement are presented that would lead to a more optimum and realistic design.

Lovejoy, Andrew E.↗
NASA NTRS2013

Integration of Mirror Design with Suspension System using NASA's New Mirror Modeling Software

Advances in mirror fabrication is making very large space based telescopes possible. In the many applications, only monolithic mirrors meet the performance requirements. The existing and near-term planned heavy launch vehicles place a premium on lowest possible mass. Again, available and planned payload shroud size limits near term designs to 4 meter class mirror. Practical 8 meter and beyond designs could encourage planners to include larger shrouds if it can be proven that such mirrors can be manufactured. These two factors lower mass and larger mirrors, presents the classic optimization problem. There is a practical upper limit to how large a mirror can be supported by a purely kinematic mount system and be launched. This paper shows how the design of the suspension system and mirror blank needs to be designed simultaneously. We will also explore the concepts of auxiliary support systems, which act only during launch and disengage on orbit. We will define required characteristics of these systems and show how they can substantially reduce the mirror mass. The AMTD project is developing and maturing the processes for future replacements for HUBBLE, creating the design tools, validating the methods and techniques necessary to manufacture, test and launch extremely large optical missions. This paper will use the AMTD 4 meter "design point" as an illustration of the typical use of the modeler in generating the multiple models of mirror and suspension systems used during the conceptual design phase of most projects. The influence of Hexapod geometry, mirror depth, cell size and construction techniques (Exelsis Deep Core Low Temperature Fusion (c) versus Corning Frit Bonded (c) versus Schott Pocket Milled Zerodur (c) in this particular study) are being evaluated. Due to space and time consideration we will only be able to present snippets of the study in this paper. The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond.

Arnold, William↗
NASA NTRS2014

Intuitive Tools for the Design and Analysis of Communication Payloads for Satellites

In an effort to make future communications satellite payload design more efficient and accessible, two tools were created with intuitive graphical user interfaces (GUIs). The first tool allows payload designers to graphically design their payload by using simple drag and drop of payload components onto a design area within the program. Information about each picked component is pulled from a database of common space-qualified communication components sold by commerical companies. Once a design is completed, various reports can be generated, such as the Master Equipment List. The second tool is a link budget calculator designed specifically for ease of use. Other features of this tool include being able to access a database of NASA ground based apertures for near Earth and Deep Space communication, the Tracking and Data Relay Satellite System (TDRSS) base apertures, and information about the solar system relevant to link budget calculations. The link budget tool allows for over 50 different combinations of user inputs, eliminating the need for multiple spreadsheets and the user errors associated with using them. Both of the aforementioned tools increase the productivity of space communication systems designers, and have the colloquial latitude to allow non-communication experts to design preliminary communication payloads.

communication↗