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NASA NTRS2000

Power System Options Evaluated for the Radiation and Technology Demonstration Mission

The Radiation and Technology Demonstration (RTD) Mission is under joint study by three NASA Centers: the NASA Johnson Space Center, the NASA Goddard Space Flight Center, and the NASA Glenn Research Center at Lewis Field. This Earth-orbiting mission, which may launch on a space shuttle in the first half of the next decade, has the primary objective of demonstrating high-power electric thruster technologies. Secondary objectives include better characterization of Earth's Van Allen trapped-radiation belts, measurement of the effectiveness of the radiation shielding for human protection, measurement of radiation effects on advanced solar cells, and demonstration of radiation-tolerant microelectronics. During the mission, which may continue up to 1 year, the 2000-kg RTD spacecraft will first spiral outward from the shuttle-deployed, medium-inclination, low Earth orbit. By the phased operation of a 10-kW Hall thruster and a 10-kW Variable Specific Impulse Magneto-Plasma Rocket, the RTD spacecraft will reach a low-inclination Earth orbit with a radius greater than five Earth radii. This will be followed by an inward spiraling orbit phase when the spacecraft deploys 8 to 12 microsatellites to map the Van Allen belts. The mission will conclude in low Earth orbit with the possible retrieval of the spacecraft by the space shuttle. A conceptual RTD spacecraft design showing two photovoltaic (PV) array wings, the Hall thruster with propellant tanks, and stowed microsatellites is presented. Early power system studies assessed five different PV array design options coupled with a 120-Vdc power management and distribution system (PMAD) and secondary lithium battery energy storage. Array options include (1) state-of-the-art 10-percent efficient three-junction amorphous SiGe thin-film cells on thin polymer panels deployed with an inflatable (or articulated) truss, (2) SCARLET array panels, (3) commercial state-of-the-art, planar PV array rigid panels with 25-percent efficient, three-junction GaInP2/GaAs/Ge solar cells, (4) rigid panels with 25-percent efficient, three-junction GaInP2/GaAs/Ge solar cells, in a 2 -concentrator trough configuration, and (5) thin polymer panels with 25-percent efficient, three-junction GaInP2/GaAs/Ge solar cells deployed with an inflatable (or articulated) truss. To assess the relative merits of these PV array design options, the study group developed a dedicated Fortran code to predict power system performance and estimate system mass. This code also modeled Earth orbital environments important for accurately predicting PV array performance. The most important environmental effect, solar cell radiation degradation, was calculated from electron-proton fluence input from the industry standard AE8/AP8 trapped radiation models and the concept of damage equivalence. Power systems were sized to provide 10 kW of thruster power and approximately 1 kW of spacecraft power at end of life. Of the five PV array design options, the option 1 (thin-film cells) power system was the most massive 590 kg, whereas the option 4 (trough concentrator) power system was the lightest 260 kg. Arguably, the lowest cost would come from the option 3 (commercial array panels) power system with an acceptable, albeit greater, system mass of 320 kg. Predicted power system performance during the spiral-out mission phase is shown the preceding graph for the option 5 (flexible-panel) array. From the results, the radiation-induced power loss over time is evident as the spacecraft slowly spirals outward through the trapped proton belt. The importance of the spiral trip time is also evident in the two curves representing 74-day and 182-day spiral-out periods. The longer spiral time introduces a beginning-of-life power oversizing penalty greater than 1 kW. Future studies will analyze power system performance and mass with a 50-Vdc power management and distribution architecture favorable to the VASIMR thruster and longer missions.

Kerslake, Thomas W.↗

NASA NTRS2005

In-Vacuum Photogrammetry of a 10-Meter Solar Sail

In July 2004, a 10-meter solar sail structure developed by L Garde, Inc. was tested in vacuum at the NASA Glenn 30-meter Plum Brook Space Power Facility in Sandusky, Ohio. The three main objections of the test were to demonstrate unattended deployment from a stowed configuration, to measure the deployed shape of the sail at both ambient and cryogenic room temperatures, and to measure the deployed structural dynamic characteristics (vibration modes). This paper summarizes the work conducted to fulfill the second test objective. The deployed shape was measured photogrammetrically in vacuum conditions with four 2-megapixel digital video cameras contained in custom made pressurized canisters. The canisters included high-intensity LED ring lights to illuminate a grid of retroreflective targets distributed on the solar sail. The test results closely matched pre-test photogrammetry numerical simulations and compare well with ABAQUS finite-element model predictions.

Meyer, Chris G.↗

NASA NTRS2003

Thin Film Technology Development for the Powersphere

The Aerospace Corporation, NASA Glenn Research Center, Lockheed-Martin, and ILC Dover over the past two years have been engaged in developing a Multifunctional Inflatable Structure for the Powersphere Concept under contract with NASA (NAS3-01115). The Powersphere concept consists of a relatively large spherical solar array, which would be deployed from a microsatellite. The Powersphere structure and the deployment method was patented by the Aerospace Corporation (U.S. Patent Numbers 6,284,966 B 1 and 6,3 18,675). The work on this project has resulted in a number of technological innovations in the state of the art for integrating flexible thin-film solar cells with flex circuit harness technology and inflatable ultraviolet-light-rigidizable structures. The specific power, specific volume, for the Powersphere are presented in Figures 1 and 2 as a function of solar cell technology and efficiency. The Powersphere will enable microsatellite missions across NASA enterprises and DoD missions by providing ample electric power at an affordable cost. The Powersphere design provides attitude-independent electric power and thermal control for an enclosed microsatellite payload. The design is scalable, robust in high radiation environments and provides sufficient electric power to allow the use of electric propulsion. Electric propulsion enables precise positioning of microsatellites which is required for inspectors that would be deployed to inspect the International Space Station, Space Shuttle or large unmanned spacecraft. The Powersphere allows for efficient launch packaging versus deployed volume as shown in Figure 3.

Simburger, Edward J.↗

NASA NTRS2005

Thermal System Verification and Model Validation for NASA's Cryogenic Passively Cooled James Webb Space Telescope (JWST)

A thorough and unique thermal verification and model validation plan has been developed for NASA s James Webb Space Telescope. The JWST observatory consists of a large deployed aperture optical telescope passively cooled to below 50 Kelvin along with a suite of several instruments passively and actively cooled to below 37 Kelvin and 7 Kelvin, respectively. Passive cooling to these extremely low temperatures is made feasible by the use of a large deployed high efficiency sunshield and an orbit location a! !he L2 Lagrange p~in!. Another enabling feature is the scale or size of the observatory that allows for large radiator sizes that are compatible with the expected power dissipation of the instruments and large format Mercury Cadmium Telluride (HgCdTe) detector arrays. This passive cooling concept is simple, reliable, and mission enabling when compared to the alternatives of mechanical coolers and stored cryogens. However, these same large scale observatory features, which make passive cooling viable, also prevent the typical flight configuration fully-deployed thermal balance test that is the keystone to most space missions thermal verification plan. JWST is simply too large in its deployed configuration to be properly thermal balance tested in the facilities that currently exist. This reality, when combined with a mission thermal concept with little to no flight heritage, has necessitated the need for a unique and alternative approach to thermal system verification and model validation. This paper describes the thermal verification and model validation plan that has been developed for JWST.

Parrish, Keith↗

NASA NTRS2005

Thermal System Verification and Model Validation for NASA's Cryogenic Passively Cooled James Webb Space Telescope

A thorough and unique thermal verification and model validation plan has been developed for NASA s James Webb Space Telescope. The JWST observatory consists of a large deployed aperture optical telescope passively cooled to below 50 Kelvin along with a suite of several instruments passively and actively cooled to below 37 Kelvin and 7 Kelvin, respectively. Passive cooling to these extremely low temperatures is made feasible by the use of a large deployed high efficiency sunshield and an orbit location at the L2 Lagrange point. Another enabling feature is the scale or size of the observatory that allows for large radiator sizes that are compatible with the expected power dissipation of the instruments and large format Mercury Cadmium Telluride (HgCdTe) detector arrays. This passive cooling concept is simple, reliable, and mission enabling when compared to the alternatives of mechanical coolers and stored cryogens. However, these same large scale observatory features, which make passive cooling viable, also prevent the typical flight configuration fully-deployed thermal balance test that is the keystone to most space missions thermal verification plan. JWST is simply too large in its deployed configuration to be properly thermal balance tested in the facilities that currently exist. This reality, when combined with a mission thermal concept with little to no flight heritage, has necessitated the need for a unique and alternative approach to thermal system verification and model validation. This paper describes the thermal verification and model validation plan that has been developed for JWST. The plan relies on judicious use of cryogenic and thermal design margin, a completely independent thermal modeling cross check utilizing different analysis teams and software packages, and finally, a comprehensive set of thermal tests that occur at different levels of JWST assembly. After a brief description of the JWST mission and thermal architecture, a detailed description of the three aspects of the thermal verification and model validation plan is presented.

Cleveland, Paul E.↗

NASA NTRSDate not supplied

Aerodynamic Decelerators for Planetary Exploration: Past, Present, and Future

In this paper, aerodynamic decelerators are defined as textile devices intended to be deployed at Mach numbers below five. Such aerodynamic decelerators include parachutes and inflatable aerodynamic decelerators (often known as ballutes). Aerodynamic decelerators play a key role in the Entry, Descent, and Landing (EDL) of planetary exploration vehicles. Among the functions performed by aerodynamic decelerators for such vehicles are deceleration (often from supersonic to subsonic speeds), minimization of descent rate, providing specific descent rates (so that scientific measurements can be obtained), providing stability (drogue function - either to prevent aeroshell tumbling or to meet instrumentation requirements), effecting further aerodynamic decelerator system deployment (pilot function), providing differences in ballistic coefficients of components to enable separation events, and providing height and timeline to allow for completion of the EDL sequence. Challenging aspects in the development of aerodynamic decelerators for planetary exploration missions include: deployment in the unusual combination of high Mach numbers and low dynamic pressures, deployment in the wake behind a blunt-body entry vehicle, stringent mass and volume constraints, and the requirement for high drag and stability. Furthermore, these aerodynamic decelerators must be qualified for flight without access to the exotic operating environment where they are expected to operate. This paper is an introduction to the development and application of aerodynamic decelerators for robotic planetary exploration missions (including Earth sample return missions) from the earliest work in the 1960s to new ideas and technologies with possible application to future missions. An extensive list of references is provided for additional study.

Juan R Cruz↗

NASA NTRS2007

Mars Science Laboratory: Entry, Descent, and Landing System Performance

In 2010, the Mars Science Laboratory (MSL) mission will pioneer the next generation of robotic Entry, Descent, and Landing (EDL) systems, by delivering the largest and most capable rover to date to the surface of Mars. To do so, MSL will fly a guided lifting entry at a lift-to-drag ratio in excess of that ever flown at Mars, deploy the largest parachute ever at Mars, and perform a novel Sky Crane maneuver. Through improved altitude capability, increased latitude coverage, and more accurate payload delivery, MSL is allowing the science community to consider the exploration of previously inaccessible regions of the planet. The MSL EDL system is a new EDL architecture based on Viking heritage technologies and designed to meet the challenges of landing increasing massive payloads on Mars. In accordance with level-1 requirements, the MSL EDL system is being designed to land an 850 kg rover to altitudes as high as 1 km above the Mars Orbiter Laser Altimeter defined areoid within 10 km of the desired landing site. Accordingly, MSL will enter the largest entry mass, fly the largest 70 degree sphere-cone aeroshell, generate the largest hypersonic lift-to-drag ratio, and deploy the largest Disk-Gap-Band supersonic parachute of any previous mission to Mars. Major EDL events include a hypersonic guided entry, supersonic parachute deploy and inflation, subsonic heatshield jettison, terminal descent sensor acquisition, powered descent initiation, sky crane terminal descent, rover touchdown detection, and descent stage flyaway. Key performance metrics, derived from level-1 requirements and tracked by the EDL design team to indicate performance capability and timeline margins, include altitude and range at parachute deploy, time on radar, and propellant use. The MSL EDL system, which will continue to develop over the next three years, will enable a notable extension in the advancement of Mars surface science by delivering more science capability than ever before to the surface of Mars. This paper describes the current MSL EDL system performance as predicted by end-to-end EDL simulations, highlights the sensitivity of this baseline performance to several key environmental assumptions, and discusses some of the challenges faced in delivering such an unprecedented rover payload to the surface of Mars.

Way, David W.↗

NASA NTRS2007

Structural Bus and Release Mechanisms on the ST5 Satellites: Summary and Status

The Space Technology 5 Mechanical System met the challenge of packaging a fully functional science and technology satellite system with its Deployer mechanism into a compact 0.07cu m volume. Three 25 kg satellites were orbited in constellation in March, 2006. The ST5 mechanical system is composed of 1) The Structural Bus; 2) Magnetometer Instrument Boom 3) Spacecraft Deployer Release Mechanism This system includes a highly integrated electronics enclosure as a multifunctional structure; a lightweight, magnetically clean Magnetometer Boom; the first use of Nitinol Shape-Memory Alloy trigger devices for deploying multiple spacecraft; an innovative compliant mount for the umbilical connector and a Deployer mechanism that imparts both separation velocity and mission spin rate to three constellation flying satellites These elements employed cutting-edge design and analysis tools, state-of-the-art testing facilities and proven engineering techniques to meet stringent performance criteria, enabling the mission s success.

Rossoni, Peter↗

NASA NTRS2008

Advanced Precipitation Radar Antenna to Measure Rainfall From Space

To support NASA s planned 20-year mission to provide sustained global precipitation measurement (EOS-9 Global Precipitation Measurement (GPM)), a deployable antenna has been explored with an inflatable thin-membrane structure. This design uses a 5.3 5.3-m inflatable parabolic reflector with the electronically scanned, dual-frequency phased array feeds to provide improved rainfall measurements at 2.0-km horizontal resolution over a cross-track scan range of up to 37 , necessary for resolving intense, isolated storm cells and for reducing the beam-filling and spatial sampling errors. The two matched radar beams at the two frequencies (Ku and Ka bands) will allow unambiguous retrieval of the parameters in raindrop size distribution. The antenna is inflatable, using rigidizable booms, deployable chain-link supports with prescribed curvatures, a smooth, thin-membrane reflecting surface, and an offset feed technique to achieve the precision surface tolerance (0.2 mm RMS) for meeting the low-sidelobe requirement. The cylindrical parabolic offset-feed reflector augmented with two linear phased array feeds achieves dual-frequency shared-aperture with wide-angle beam scanning and very low sidelobe level of -30 dB. Very long Ku and Ka band microstrip feed arrays incorporating a combination of parallel and series power divider lines with cosine-over-pedestal distribution also augment the sidelobe level and beam scan. This design reduces antenna mass and launch vehicle stowage volume. The Ku and Ka band feed arrays are needed to achieve the required cross-track beam scanning. To demonstrate the inflatable cylindrical reflector with two linear polarizations (V and H), and two beam directions (0deg and 30deg), each frequency band has four individual microstrip array designs. The Ku-band array has a total of 166x2 elements and the Ka-band has 166x4 elements with both bands having element spacing about 0.65 lambda(sub 0). The cylindrical reflector with offset linear array feeds reduces the complexity from "NxN" transmit/receive (T/R) modules of a conventional planar-phased array to just "N" T/R modules. The antenna uses T/R modules with electronic phase-shifters for beam steering. The offset reflector does not provide poor cross-polarization like a double- curved offset reflector would, and it allows the wide scan angle in one plane required by the mission. Also, the cylindrical reflector with two linear array feeds provides dual-frequency performance with a single, shared aperture. The aperture comprises a reflective surface with a focal length of 1.89 m and is made from aluminized Kapton film. The reflective surface is of uniform thickness in the range of a few thousandths of an inch and is attached to the chain-link support structure via an adjustable suspension system. The film aperture rolls up, together with the chain-link structure, for launch and can be deployed in space by the deployment of the chain-link structure.

Rahmat-Samii, Yahya↗

NASA NTRS2008

NanoSail-D: The First Flight Demonstration of Solar Sails for Nanosatellites

The NanoSail-D mission is currently scheduled for launch onboard a Falcon Launch Vehicle in the late June 2008 timeframe. The NanoSail-D, a CubeSat-class satellite, will consist of a sail subsystem stowed in a Cubesat 2U volume integrated with a CubeSat 1U volume bus provided by the NASA Ames Research Center (ARC). Shortly after deployment of the NanoSail-D from a Poly Picosatellite Orbital Deployer (P-POD) ejection system, the solar sail will deploy and mission operations will commence. This demonstration flight has two primary mission objectives: 1) to successfully stow and deploy the sail and 2) to demonstrate de-orbit functionality. Given a nearterm opportunity for launch, the project was met with the challenge of delivering the flight hardware in approximately six months, which required a significant constraint on flight system functionality. As a consequence, passive attitude stabilization will be achieved using permanent magnets to de-tumble and orient the body with the magnetic field lines and then rely on atmospheric drag to passively stabilize the sailcraft in an essentially maximum drag attitude. This paper will present an introduction to solar sail propulsion systems, overview the NanoSail-D spacecraft, describe the performance analysis for the passive attitude stabilization, and present a prediction of flight data results from the mission.

Whorton, Mark↗

NASA NTRS2006

Mars Science Laboratory: Entry, Descent, and Landing System Performance

Way, David W.↗

NASA NTRS2009

Protocol for Communication Networking for Formation Flying

An application-layer protocol and a network architecture have been proposed for data communications among multiple autonomous spacecraft that are required to fly in a precise formation in order to perform scientific observations. The protocol could also be applied to other autonomous vehicles operating in formation, including robotic aircraft, robotic land vehicles, and robotic underwater vehicles. A group of spacecraft or other vehicles to which the protocol applies could be characterized as a precision-formation- flying (PFF) network, and each vehicle could be characterized as a node in the PFF network. In order to support precise formation flying, it would be necessary to establish a corresponding communication network, through which the vehicles could exchange position and orientation data and formation-control commands. The communication network must enable communication during early phases of a mission, when little positional knowledge is available. Particularly during early mission phases, the distances among vehicles may be so large that communication could be achieved only by relaying across multiple links. The large distances and need for omnidirectional coverage would limit communication links to operation at low bandwidth during these mission phases. Once the vehicles were in formation and distances were shorter, the communication network would be required to provide high-bandwidth, low-jitter service to support tight formation-control loops. The proposed protocol and architecture, intended to satisfy the aforementioned and other requirements, are based on a standard layered-reference-model concept. The proposed application protocol would be used in conjunction with conventional network, data-link, and physical-layer protocols. The proposed protocol includes the ubiquitous Institute of Electrical and Electronics Engineers (IEEE) 802.11 medium access control (MAC) protocol to be used in the datalink layer. In addition to its widespread and proven use in diverse local-area networks, this protocol offers both (1) a random- access mode needed for the early PFF deployment phase and (2) a time-bounded-services mode needed during PFF-maintenance operations. Switching between these two modes could be controlled by upper-layer entities using standard link-management mechanisms. Because the early deployment phase of a PFF mission can be expected to involve multihop relaying to achieve network connectivity (see figure), the proposed protocol includes the open shortest path first (OSPF) network protocol that is commonly used in the Internet. Each spacecraft in a PFF network would be in one of seven distinct states as the mission evolved from initial deployment, through coarse formation, and into precise formation. Reconfiguration of the formation to perform different scientific observations would also cause state changes among the network nodes. The application protocol provides for recognition and tracking of the seven states for each node and for protocol changes under specified conditions to adapt the network and satisfy communication requirements associated with the current PFF mission phase. Except during early deployment, when peer-to-peer random access discovery methods would be used, the application protocol provides for operation in a centralized manner.

Jennings, Esther↗

NASA NTRS2009

Ultra-Large Solar Sail

UltraSail is a next-generation ultra-large (km2 class) sail system. Analysis of the launch, deployment, stabilization, and control of these sails shows that high-payload-mass fractions for interplanetary and deep-space missions are possible. UltraSail combines propulsion and control systems developed for formation-flying microsatellites with a solar sail architecture to achieve controllable sail areas approaching 1 km2. Electrically conductive CP-1 polyimide film results in sail subsystem area densities as low as 5 g/m2. UltraSail produces thrust levels many times those of ion thrusters used for comparable deep-space missions. The primary innovation involves the near-elimination of sail-supporting structures by attaching each blade tip to a formation- flying microsatellite, which deploys the sail and then articulates the sail to provide attitude control, including spin stabilization and precession of the spin axis. These microsatellite tips are controlled by microthrusters for sail-film deployment and mission operations. UltraSail also avoids the problems inherent in folded sail film, namely stressing, yielding, or perforating, by storing the film in a roll for launch and deployment. A 5-km long by 2 micrometer thick film roll on a mandrel with a 1 m circumference (32 cm diameter) has a stored thickness of 5 cm. A 5 m-long mandrel can store a film area of 25,000 m2, and a four-blade system has an area of 0.1 sq km.

Burton, Rodney↗

NASA NTRS2009

Improved Method of Design for Folding Inflatable Shells

An improved method of designing complexly shaped inflatable shells to be assembled from gores was conceived for original application to the inflatable outer shell of a developmental habitable spacecraft module having a cylindrical mid-length section with toroidal end caps. The method is also applicable to inflatable shells of various shapes for terrestrial use. The method addresses problems associated with the assembly, folding, transport, and deployment of inflatable shells that may comprise multiple layers and have complex shapes that can include such doubly curved surfaces as toroids and spheres. One particularly difficult problem is that of mathematically defining fold lines on a gore pattern in a double- curvature region. Moreover, because the fold lines in a double-curvature region tend to be curved, there is a practical problem of how to implement the folds. Another problem is that of modifying the basic gore shapes and sizes for the various layers so that when they are folded as part of the integral structure, they do not mechanically interfere with each other at the fold lines. Heretofore, it has been a common practice to design an inflatable shell to be assembled in the deployed configuration, without regard for the need to fold it into compact form. Typically, the result has been that folding has been a difficult, time-consuming process resulting in a An improved method of designing complexly shaped inflatable shells to be assembled from gores was conceived for original application to the inflatable outer shell of a developmental habitable spacecraft module having a cylindrical mid-length section with toroidal end caps. The method is also applicable to inflatable shells of various shapes for terrestrial use. The method addresses problems associated with the assembly, folding, transport, and deployment of inflatable shells that may comprise multiple layers and have complex shapes that can include such doubly curved surfaces as toroids and spheres. One particularly difficult problem is that of mathematically defining fold lines on a gore pattern in a double- curvature region. Moreover, because the fold lines in a double-curvature region tend to be curved, there is a practical problem of how to implement the folds. Another problem is that of modifying the basic gore shapes and sizes for the various layers so that when they are folded as part of the integral structure, they do not mechanically interfere with each other at the fold lines. Heretofore, it has been a common practice to design an inflatable shell to be assembled in the deployed configuration, without regard for the need to fold it into compact form. Typically, the result has been that folding has been a difficult, time-consuming process resulting in a

Johnson, Christopher J.↗

NASA NTRS2010

Inflatable Tubular Structures Rigidized with Foams

Inflatable tubular structures that have annular cross sections rigidized with foams, and the means of erecting such structures in the field, are undergoing development. Although the development effort has focused on lightweight structural booms to be transported in compact form and deployed in outer space, the principles of design and fabrication are also potentially applicable to terrestrial structures, including components of ultralightweight aircraft, lightweight storage buildings and shelters, lightweight insulation, and sales displays. The use of foams to deploy and harden inflatable structures was first proposed as early as the 1960s, and has been investigated in recent years by NASA, the U.S. Air Force Research Laboratory, industry, and academia. In cases of deployable booms, most of the investigation in recent years has focused on solid cross sections, because they can be constructed relatively easily. However, solid-section foam-filled booms can be much too heavy for some applications. In contrast, booms with annular cross sections according to the present innovation can be tailored to obtain desired combinations of stiffness and weight through choice of diameters, wall thicknesses, and foam densities. By far the most compelling advantage afforded by this innovation is the possibility of drastically reducing weights while retaining or increasing the stiffnesses, relative to comparable booms that have solid foamfilled cross sections. A typical boom according to this innovation includes inner and outer polyimide film sleeves to contain foam that is injected between them during deployment.

Tinker, Michael L.↗

NASA NTRS2010

Gravity-Off-loading System for Large-Displacement Ground Testing of Spacecraft Mechanisms

Gravity-off-loading of deployable spacecraft mechanisms during ground testing is a long-standing problem. Deployable structures which are usually too weak to support their own weight under gravity require a means of gravity-off-loading as they unfurl. Conventional solutions to this problem have been helium-filled balloons or mechanical pulley/counterweight systems. These approaches, however, suffer from the deleterious effects of added inertia or friction forces. The changing form factor of the deployable structure itself and the need to track the trajectory of the center of gravity also pose a challenge to these conventional technologies. This paper presents a novel testing apparatus for high-fidelity zero-gravity simulation for special application to deployable space structures such as solar arrays, magnetometer booms, and robotic arms in class 100,000 clean room environments

Han, Olyvia↗

NASA NTRS2010

Reusable Hot-Wire Cable Cutter

During the early development stage of balloon deployment systems for missions, nichrome wire cable cutters were often used in place of pyro-actuated cutters. Typically, a nichrome wire is wrapped around a bundle of polymer cables with a low melting point and connected to a relay-actuated electric circuit. The heat from the nichrome reduces the strength of the cable bundle, which quickly breaks under a mechanical load and can thus be used as a release mechanism for a deployment system. However, the use of hand-made heated nichrome wire for cutters is not very reliable. Often, the wrapped nichrome wire does not cut through the cable because it either pulls away from its power source or does not stay in contact with the cable being cut. Because nichrome is not readily soldered to copper wire, unreliable mechanical crimps are often made to connect the nichrome to an electric circuit. A self-contained device that is reusable and reliable was developed to sever cables for device release or deployment. The nichrome wire in this new device is housed within an enclosure to prevent it from being damaged by handling. The electric power leads are internally connected within the unit to the nichrome wire using a screw terminal connection. A bayonet plug, a quick and secure method of connecting the cutter to the power source, is used to connect the cutter to the power leads similar to those used in pyro-cutter devices. A small ceramic tube [0.25-in. wide 0.5-in. long (.6.4-mm wide 13-mm long)] houses a spiraled nichrome wire that is heated when a cable release action is required. The wire is formed into a spiral coil by wrapping it around a mandrel. It is then laid inside the ceramic tube so that it fits closely to the inner surface of the tube. The ceramic tube provides some thermal and electrical insulation so that most of the heat generated by the wire is directed toward the cable bundle in the center of the spiral. The ceramic tube is cemented into an aluminum block, which holds it in position. The leads of the nichrome wire are attached to screw terminals that connect them to power leads. A bayonet plug mounted at the bottom of the rectangular block connects the power leads to a relay circuit. A thin aluminum shell encloses the entire structure, leaving access points to attach to the bayonet plug and to feed a cable into the cylinder. The access holes for the deployment cable are a smaller diameter than the nichrome coil to prevent the cable from coming in direct contact with the nichrome when loaded. It uses the same general method of severing a cable with a heated wire as was used previously, but implements it in such a way that it is more reliable and less prone to failure. It creates a mechanism to create repeatability that was nonexistent in the previous method.

Pauken, Michael T.↗

NASA NTRS2011

Mars Science Laboratory Entry Guidance

The Mars Science Laboratory will be the first Mars mission to attempt a guided entry with the objective of safely delivering the entry vehicle to a survivable parachute deploy state within 12.5 km of the pre-designated parachute deploy coordinates. The Entry Terminal Point Controller guidance algorithm is derived from the final phase Apollo Command Module guidance and, like Apollo, modulates the bank angle to control range based on deviations in range, altitude rate, and drag acceleration from a reference trajectory. For application to Mars landers which must make use of the tenuous Martian atmosphere, it is critical to balance the lift of the vehicle to minimize the range while still ensuring a safe deploy altitude. An overview of the process to generate optimized guidance settings is presented, discussing improvements made over the last nine years. Performance tradeoffs between ellipse size and deploy altitude will be presented, along with imposed constraints of entry acceleration and heating. Performance sensitivities to the bank reversal deadbands, heading alignment, attitude initialization error, and entry delivery errors are presented.

Mendeck, Gavin F.↗