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Poison control tube and manifold system for reactivity control of tungsten water moderated rocket reactor
Chemical poison control tube and manifold used for reactivity control of rocket reactor
As a member of the Space Suit Assembly Development Engineering Team, I designed and built test equipment systems to support the development of the next generation of advanced space suits. During space suit testing it is critical to supply the subject with two functions: (1) cooling to remove metabolic heat, and (2) breathing air to pressurize the space suit. The objective of my first project was to design, build, and certify an improved Space Suit Cooling System for manned testing in a 1‐G environment. This design had to be portable and supply a minimum cooling rate of 2500 BTU/hr. The Space Suit Cooling System is a robust, portable system that supports very high metabolic rates. It has a highly adjustable cool rate and is equipped with digital instrumentation to monitor the flowrate and critical temperatures. It can supply a variable water temperature down to 34 deg., and it can generate a maximum water flowrate of 2.5 LPM. My next project was to design and build a Breathing Air System that was capable of supply facility air to subjects wearing the Z‐2 space suit. The system intakes 150 PSIG breathing air and regulates it to two operating pressures: 4.3 and 8.3 PSIG. It can also provide structural capabilities at 1.5x operating pressure: 6.6 and 13.2 PSIG, respectively. It has instrumentation to monitor flowrate, as well as inlet and outlet pressures. The system has a series of relief valves to fully protect itself in case of regulator failure. Both projects followed a similar design methodology. The first task was to perform research on existing concepts to develop a sufficient background knowledge. Then mathematical models were developed to size components and simulate system performance. Next, mechanical and electrical schematics were generated and presented at Design Reviews. After the systems were approved by the suit team, all the hardware components were specified and procured. The systems were then packaged, fabricated, and thoroughly tested. The next step was to certify the equipment for manned used, which included generating a Hazard Analysis and giving a presentation to the Test Readiness Review Board. Both of these test support systems will perform critical roles in the development of next‐generation space suits. They will used on a regular basis to test the NASA's new Z‐2 Space Suit. The Space Suit Cooling System is now the primary cooling system for all advanced suit tests.
To examine the issues of optimum human-machine mixtures for orbital assembly operations, a full six degree-of-freedom teleoperator system for assembly of large space structures has been developed by the Space Systems Laboratory. This consists of a free-flying neutrally buoyant Beam Assembly Teleoperator (BAT) with two manipulators, and a modular Integrated Control Station (ICS). The design and configuration of both the BAT and the ICS are described in some detail in this paper. In addition, qualitative results from early tests of the system are presented. These tests concentrated mostly on free-flying operations and grasping. Future tests will involve complete teleoperated assembly.
This paper presents an overview of the Galileo Project's environmental test and analysis program during the spacecraft development phase - October 1978 through launch in October 1989. After describing the top-level objectives of the program, summaries of-the approach, requirements, and margins are provided. Examples of assembly- and system-level test results are given for both the pre-1986 (direct mission) testing and the post-1986 (Venus-Earth-Earth gravity assist mission) testing, including dynamic, thermal, electromagnetic compatibility (EMC), and magnetic. The approaches and results for verifying by analysis that the requirements of certain environments (e.g., radiation, micrometeoroids, and single event upsets) are satisfied are presented. The environmental program implemented on Galileo satisfied the spirit and intent of the requirements imposed by the Project during the spacecraft's development. The lessons learned from the Galileo environmental program are discussed in this paper.
As the Constellation Program enters its fourth year, the Ares Projects have made substantial progress toward sending human explorers beyond Earth orbit. The Ares I crew launch vehicle, which will take six astronauts or cargo to the International Space Station or four astronauts to rendezvous with Ares V for missions to the Moon, is the first human-rated vehicle NASA has developed in over 30 years. Since the Exploration Systems Architecture Study in 2005, the Ares Projects have completed a successful system requirements review, system definition review, and preliminary design review for the Ares I crew launch vehicle. The Ares I elements are well into development, beginning with the Shuttle-derived, five-segment solid rocket motor that will provide first-stage propulsion. The first stage team has poured its first production simulation article motor and will be pouring and firing the first five-segment development motor in 2009. Large-scale tooling has been installed and tested to produce propellant tanks for the liquid-fuel upper stage at Marshall Space Flight Center (MSFC) in Alabama. The initial upper stage units and main propulsion test article will be manufactured and tested at MSFC before transferring to Michoud Assembly Facility in Louisiana. The upper stage engine team has completed powerpack testing using Apollo J-2 heritage hardware and begun construction of a new altitude test stand at Stennis Space Center in Mississippi. The flight and integrated testing group has designed and built hardware for the Ares I-X test flight scheduled for 2009, as well as begun refurbishing existing infrastructure to support ground testing. Additionally, a base configuration has been selected for the Ares V cargo launch vehicle, which will send the Altair lunar lander and Orion to the Moon. Today, the Ares Projects are well on the way to building America s next generation of exploration-capable launch vehicles.
To meet the life and reliability requirements of five to ten year space missions, a new solar array drive mechanism for 3-axis stabilized vehicles has been developed and is undergoing life testing. The drive employs a redundant lubrication system to increase its reliability. An overrunning clutch mechanism is used to permit block redundant application of two or more drives to a common array drive shaft. Two prototype actuator and clutch assemblies, in continuous vacuum life test under load at 10 to the minus 8th power torr for more than sixteen months, have each accumulated more than 34,000 output revolutions without anomaly, the equivalent of more than seven years of operation in a 1000 km orbit or nearly ninety-five years at synchronous altitude.
Significant advancements have been made in the development of lightweight, high performance, carbon-carbon heat pipes for space nuclear power applications. The subject program has progressed through the concept definition and feasibility analysis stages to the current test article component fabrication and assembly phase. This concept utilizes a carbon-carbon tube with integrally woven fins as the primary structural element and radiative surface, Nb-1Zr liners to contain a potassium working fluid, and welded end caps and fill tubes. Various tests have been performed in the development of suitable liner bonding techniques and in the assessment of material stability.
Two cover mechanisms were designed and developed for the Extreme Ultraviolet Explorer (EUVE) science payload to keep the EUVE telescope mirrors and detectors sealed from the atmospheric environment until the spacecraft was placed into orbit. There were four telescope front covers and seven motorized detector covers on the EUVE science payload. The EUVE satellite was launched into orbit in June 1992 and all the covers operated successfully after launch. This success can be attributed to high design margins and extensive testing at each level of assembly. This paper described the design of the telescope front covers and the motorized detector covers. This paper also discusses some of the many design considerations and modifications made as performance and reliability problems became apparent from each phase of testing.
The Ares I Crew Launch Vehicle (CLV) is being developed by the U.S. National Aeronautics and Space Administration (NASA) to provide crew access to the International Space Station (ISS) and, together with the Ares V Cargo Launch Vehicle (CaLV), serves as one component of a future launch capability for human exploration of the Moon. During the system requirements definition process and early design cycles, NASA defined and began implementing plans for integrated ground and flight testing necessary to achieve the first human launch of Ares I. The individual Ares I flight hardware elements: the first stage five segment booster (FSB), upper stage, and J-2X upper stage engine, will undergo extensive development, qualification, and certification testing prior to flight. Key integrated system tests include the Main Propulsion Test Article (MPTA), acceptance tests of the integrated upper stage and upper stage engine assembly, a full-scale integrated vehicle dynamic test (IVDT), aerodynamic testing to characterize vehicle performance, and integrated testing of the avionics and software components. The Ares I-X development flight test will provide flight data to validate engineering models for aerodynamic performance, stage separation, structural dynamic performance, and control system functionality. The Ares I-Y flight test will validate ascent performance of the first stage, stage separation functionality, and a highaltitude actuation of the launch abort system (LAS) following separation. The Orion-1 flight test will be conducted as a full, un-crewed, operational flight test through the entire ascent flight profile prior to the first crewed launch.
In an effort to design the next generation Lunar suit, NASA has initiated a series of tests aimed at understanding the human physiological and biomechanical affects of space suits under a variety of conditions. The first of these tests was the EVA Walkback Test (ICES 2007-01-3133). NASA-JSC assembled a multi-disciplinary team to conduct the second test of the series, titled Integrated Suit Test 1 (IST-1), from March 6 through July 24, 2007. Similar to the Walkback Test, this study was performed with the Mark III (MKIII) EVA Technology Demonstrator suit, a treadmill, and the Partial Gravity Simulator in the Space Vehicle Mock-Up Facility at Johnson Space Center. The data collected for IST-1 included metabolic rates, ground reaction forces, biomechanics, and subjective workload and controllability feedback on both suited and unsuited (shirt-sleeve) astronaut subjects. For IST-1 the center of gravity was controlled to a nearly perfect position while the weight, pressure and biomechanics (waist locked vs. unlocked) were varied individually to evaluate the effects of each on the ability to perform level (0 degree incline) ambulation in simulated Lunar gravity. The detailed test methodology and preliminary key findings of IST-1 are summarized in this report.
This paper presents an overview of the Cassini Project's environmental test and analysis program during thc spacecraft development phase - October 1989 to launch on October 1997. It describes the program's objectives and requirements, summarizes the approach used to achieve them, and provides the margins that were achieved in the final design. Assembly and system level environmental tests that were performed included dynamic, thermal, electromagnetic compatibility (EMC), and magnetic tests. Analysis was used to verify that the environmental requirements of radiation, solid particles including micrometeoroids, and single event effects have been satisfied. The environmental program implemented on Cassini satisfied the spirit and intent of the requirements imposed by the Project during the spacecraft's development. The lessons learned from the Cassini environmental program are discussed.
Substantial progress was made during the past year in support of the X-33/RLV program. X-33 activity was directed towards completing the remaining design work and building hardware to support test activities. RLV work focused on the nozzle ramp and powerpack technology tasks and on supporting vehicle configuration studies. On X-33, the design activity was completed to the detail level and the remainder of the drawings were released. Component fabrication and engine assembly activity was initiated, and the first two powerpacks and the GSE and STE needed to support powerpack testing were completed. Components fabrication is on track to support the first engine assembly schedule. Testing activity included powerpack testing and component development tests consisting of thrust cell single cell testing, CWI system spider testing, and EMA valve flow and vibration testing. Work performed for RLV was divided between engine system and technology development tasks. Engine system activity focused on developing the engine system configuration and supporting vehicle configuration studies. Also, engine requirements were developed, and engine performance analyses were conducted. In addition, processes were developed for implementing reliability, mass properties, and cost controls during design. Technology development efforts were divided between powerpack and nozzle ramp technology tasks. Powerpack technology activities were directed towards the development of a prototype powerpack and a ceramic turbine technology demonstrator (CTTD) test article which will allow testing of ceramic turbines and a close-coupled gas generator design. Nozzle technology efforts were focused on the selection of a composite nozzle supplier and on the fabrication and test of composite nozzle coupons.
Presentation. An Aerojet Rocketdyne (AR) program was funded by the National Energy Technology Laboratory (NETL), part of the U.S. Department of Energy, to evaluate the benefits of an RDE in a turbine power plant system. Aerojet Rocketdyne subcontracted a variety of support for the program with efforts in modeling, diagnostic techniques, and test campaigns. Over the span of the program more than 700 hot fire tests were conducted at 4 facilities with 7 RDE assemblies. This presentation will cover results from the final test campaign conducted by Aerojet Rocketdyne.
The International Space Station (ISS) Trace Contaminant Control Subassembly (TCCS) design is based upon proven, highly reliable technology. However, because its core unit operations rely upon expendable activated charcoal and an indirectly heated high temperature catalyst, annual logistics mass, crew time, and power consumption requirements are significant. To address this situation, a unique catalytic reactor design has been developed which is suitable for retrofit into the TCCS's high temperature catalytic oxidizer (HTCO) assembly. The unique design, which employs a metallic, ultra-short channel length monolith (USCM) catalyst substrate, was tested in a flight-like TCCS HTCO assembly to investigate its performance characteristics. Test results indicate that retrofitting the TCCS with a USCM-based catalytic reactor is feasible and that it may provide significant reductions in logistics mass, crew time, and power consumption. Savings indicated by test results are up to 81% for annual logistics, 56% for crew time, and 77% for startup transient duration. In addition, its demonstrated ability to operate in a power saving mode provides up to a 43% savings in average power consumption. A summary of the USCM demonstration test objectives, approach, results, and specific benefits to the TCCS's process economics are presented,
Sierra Nevada Corporation’s Space Systems performed bearing life testing for the Scan Mirror Motor/Encoder Assembly (SMMA), part of the Scan Mirror Assembly on-board the Aerosol Polarimetry Sensor (APS) on the NASA Glory Spacecraft. The baseline bearing life test duration extended beyond the launch date for the Glory Spacecraft; a risk that the program was willing to undertake with the understanding that if any anomalies or failures occurred before the required life was achieved, then the mission objectives or operating profile could be modified on orbit to take those results into account. Even though the Glory Spacecraft failed to reach orbit during its launch in March of 2011, the bearing life testing was continued through a mutual understanding of value between Sierra Nevada Corporation and our customer; with a revised goal of testing to failure rather than completing a required number of life cycles. Life testing thus far has not only exceeded the original mission required life, but has also exceeded the published test data for Cumulative Degradation Factor (CDF) from NASA/CR-2009-215681. Many lessons were learned along the way regarding long life testing. The bearing life test has been temporarily suspended due to test support equipment issues.
The purpose of performing unsuited testing as part of a reduced gravity extravehicular (EVA) suited human performance research program is to define baseline performance. These results are then coupled with suited test results to evaluate how the suit system affects human performance at reduced gravity. The primary drawback to this approach is that previous studies used notably different systems to interface suited and unsuited subjects to overhead-suspension, partial-gravity simulators. A spreader bar (SB) assembly previously used for unsuited tests allowed limited pitch and roll of the subject, whereas the gimbal for suited tests allowed more pitch and roll, although the mass distribution led to large moments of inertia in the yaw axis. It is hypothesized that use of the same methods for offload of both unsuited and suited subjects is needed to make meaningful comparisons. A new gimbal (GIM) was designed with the idea that it could function with both suited and unsuited subjects. GIM was designed to minimize mass and moments of inertia and to be adjustable to co-locate the 3 axes of rotation with the subject s center of gravity. OBJECTIVE: To evaluate human performance differences between SB and GIM. METHODS: Ten unsuited subjects were off-loaded to 1/6-g using both interfaces. Subjects completed tasks including overground and treadmill ambulation, picking up objects, shoveling, postural stability, range of motion testing, and recovery from the kneeling and prone positions. Metabolic, biomechanical, and/or subjective data were collected based on task. RESULTS: Initial analyses suggest that subjects completed all tasks with lower levels of compensation and a more terrestrial approach to movement when suspended via GIM. With SB, subjects were not able to fall or get into a prone position and had increased difficulty both retrieving objects off the floor and with overground ambulation, especially at gait initiation, because they were unable to bend their torso. GIM shows promise as a new method.