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NASA NTRS1992

Space Station Furnace Facility Core. Requirements definition and conceptual design study. Volume 2: Technical report. Appendix 6: Technical summary reports

The Space Station Furnace Facility (SSFF) is a modular facility for materials research in the microgravity environment of the Space Station Freedom (SSF). The SSFF is designed for crystal growth and solidification research in the fields of electronic and photonic materials, metals and alloys, and glasses and ceramics and will allow for experimental determination of the role of gravitational forces in the solidification process. The facility will provide a capability for basic scientific research and will evaluate the commercial viability of low-gravity processing of selected technologically important materials. The facility is designed to support a complement of furnace modules as outlined in the Science Capabilities Requirements Document (SCRD). The SSFF is a three rack facility that provides the functions, interfaces, and equipment necessary for the processing of the furnaces and consists of two main parts: the SSFF Core Rack and the two Experiment Racks. The facility is designed to accommodate two experimenter-provided furnace modules housed within the two experiment racks, and is designed to operate these two furnace modules simultaneously. The SCRD specifies a wide range of furnace requirements and serves as the basis for the SSFF conceptual design. SSFF will support automated processing during the man-tended operations and is also designed for crew interface during the permanently manned configuration. The facility is modular in design and facilitates changes as required, so the SSFF is adept to modifications, maintenance, reconfiguration, and technology evolution.

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NASA NTRS1993

Multidisciplinary optimization of a controlled space structure using 150 design variables

A controls-structures interaction design method is presented. The method coordinates standard finite-element structural analysis, multivariable controls, and nonlinear programming codes and allows simultaneous optimization of the structure and control system of a spacecraft. Global sensitivity equations are used to account for coupling between the disciplines. Use of global sensitivity equations helps solve optimization problems that have a large number of design variables and a high degree of coupling between disciplines. The preliminary design of a generic geostationary platform is used to demonstrate the multidisciplinary optimization method. Design problems using 15, 63, and 150 design variables to optimize truss member sizes and feedback gain values are solved and the results are presented. The goal is to reduce the total mass of the structure and the vibration control system while satisfying constraints on vibration decay rate. Incorporation of the nonnegligible mass of actuators causes an essential coupling between structural design variables and control design variables.

James, Benjamin B.↗

NASA NTRS1992

Space Station Furnace Facility. Volume 1: Requirements definition and conceptual design study, executive summary

The Space Station Freedom Furnace (SSFF) Study was awarded on June 2, 1989, to Teledyne Brown Engineering (TBE) to define an advanced facility for materials research in the microgravity environment of Space Station Freedom (SSF). The SSFF will be designed for research in the solidification of metals and alloys, the crystal growth of electronic and electro-optical materials, and research in glasses and ceramics. The SSFF is one of the first 'facility' class payloads planned by the Microgravity Science and Applications Division (MSAD) of the Office of Space Science and Applications of NASA Headquarters. This facility is planned for early deployment during man-tended operations of the SSF with continuing operations through the Permanently Manned Configuration (PMC). The SSFF will be built around a general 'Core' facility which provides common support functions not provided by SSF, common subsystems which are best centralized, and common subsystems which are best distributed with each experiment module. The intent of the facility approach is to reduce the overall cost associated with implementing and operating a variety of experiments. This is achieved by reducing the launch mass and simplifying the hardware development and qualification processes associated with each experiment. The Core will remain on orbit and will require only periodic maintenance and upgrading while new Furnace Modules, samples, and consumables are developed, qualified, and transported to the SSF. The SSFF Study was divided into two phases: phase 1, a definition study phase, and phase 2, a design and development phase. The definition phase 1 is addressed. Phase 1 was divided into two parts. In the first part, the basic part of the effort, covered the preliminary definition and assessment of requirements; conceptual design of the SSFF; fabrication of mockups; and the preparation for and support of the Conceptual Design Review (CoDR). The second part, the option part, covered requirements update and documentation; refinement of the selected conceptual design through additional trades and analyses; design, fabrication, and test of the Development Model; and design, fabrication, and test of the Interrack Demonstration Unit; and support of the requirements definition review (RDR). The purpose of part 2 was to prove concept feasibility.

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NASA NTRS1991

Multi-parameter optimization tool for low-cost commercial fuselage crown designs

The work in progress for developing a methodology and software tool to aid in the optimal design of composite structures is discussed. The methodology is being developed to take advantage of the ability to tailor the composite material in conjunction with the design of the structure. The composites optimization design software UWCODA was found to be very successful in preliminary testing and early experience. UWCODA is a composites design code that uses a number of plies and fiber angles as design variables, employs maximum strain failure criteria for objective function and additional constraints, includes Boeing design tools for stiffened panels, and includes stiffener geometry in the design variables.

Zabinsky, Zelda↗

NASA NTRS1992

Loop transfer recovery for general nonminimum phase discrete time systems. II - Design

The authors consider the design of controllers for the recovery of target loop transfer function or sensitivity and complementary sensitivity functions for general nonminimum phase discrete time systems. The necessary design constraints and the available design freedom are reviewed. In view of the available freedom, possible specifications on the eigenstructure of the observer dynamic matrix are formulated. Three different types of controllers which are respectively based on prediction, current, and reduced-order estimators are considered. For each one of those controllers, three different design techniques are developed. The first one is an eigenstructure assignment scheme, while the other two are optimization-based designs. The eigenstructure assignment method yields a controller design which achieves any chosen recovery error matrix among a set of admissible recovery error matrices. On the other hand, one of the optimization-based design methods leads to a controller that achieves a recovery error matrix having the infimum H-infinity norm, while the other does the same except it achieves a recovery error matrix having the infimum H2 norm.

Chen, Ben M.↗

NASA NTRS1993

Design of deployable-truss masts for Space Station

This paper presents an overview of three deployable-truss designs that were considered for use on Space Station Freedom to deploy the solar array wings. The first design chosen early in the program was a nut-deployed coilable longeron mast which has the advantage of being lightweight and reliable, with considerable flight history. Subsequently, because of the restructure of Space Station, a second design was chosen: a lanyard-deployed FASTMast (Folding Articulated Square Truss Mast), which has improved strength and redundancy characteristics for a given stowed volume. After further definition of the load requirements during deployment, however, it became necessary to modify the deployment system, resulting in the third mast design for space station solar arrays: a nut-deployed FASTMast, which was ultimately selected to provide increased stiffness and strength during deployment. This paper presents a brief review of these mast designs and their associated deployment systems, emphasizing the trade-offs involved in selecting between them. In addition, some innovative features of the FASTMast design as it stands currently for Space Station are described, and a brief review of the test program that is underway to qualify this design for flight is included.

Bowden, Mary↗

NASA NTRS1987

Efficient optimization of integrated aerodynamic-structural design

The introduction of composite materials is having a profound effect on the design process. Because these materials permit the designer to tailor material properties to improve structural, aerodynamic and acoustic performance, they require a more integrated multidisciplinary design process. Because of the complexity of the design process numerical optimization methods are required. The present paper is focused on a major difficulty associated with the multidisciplinary design optimization process - its enormous computational cost. We consider two approaches for reducing this computational burden: (1) development of efficient methods for cross-sensitivity calculation using perturbation methods; and (2) the use of approximate numerical optimization procedures. Our efforts are concentrated upon combined aerodynamic-structural optimization. Results are presented for the integrated design of a sailplane wing. The impact of our computational procedures on the computational costs of integrated costs of integrated designs are discussed.

Haftka, R. T.↗

NASA NTRS1988

The 1987-1988 advanced space design projects: Results from the fall semester of 1987 and the spring semester of 1988

Students in Aerospace Engineering (ASE) and Mechanical Engineering (ME) at the University of Texas at Austin completed eight separate design projects under the sponsorship of the NASA/USRA Advanced Space Design Program. During the Fall semester of 1987, ASE and ME students worked on various aspects of a 'bootstrap' lunar base. ASE students concentrated on the overall definition of the base while the ME team designed a convertible lunar lander lower stage. Six design projects were executed during the spring semester of 1988. Aerospace engineering students designed a fast Mars mission crew transfer vehicle, an Earth-orbiting transportation node to support the lunar base, a lunar base construction shack/initial habitat vehicle, and carried out a systems assessment aimed at arresting ozone depletion in the Earth's atmosphere. The ME students designed a lunar surface personnel navigation system and investigated radiation shielding structures for a lunar base. The design objectives, a summary of the results, and selected comments are given concerning each of the projects. Due to the number of projects completed, the reader should refer to the text of the final project reports for additional and detailed information.

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NASA NTRS1988

Empirical studies of design software: Implications for software engineering environments

The empirical studies team of MCC's Design Process Group conducted three studies in 1986-87 in order to gather data on professionals designing software systems in a range of situations. The first study (the Lift Experiment) used thinking aloud protocols in a controlled laboratory setting to study the cognitive processes of individual designers. The second study (the Object Server Project) involved the observation, videotaping, and data collection of a design team of a medium-sized development project over several months in order to study team dynamics. The third study (the Field Study) involved interviews with the personnel from 19 large development projects in the MCC shareholders in order to study how the process of design is affected by organizationl and project behavior. The focus of this report will be on key observations of design process (at several levels) and their implications for the design of environments.

Krasner, Herb↗

NASA NTRS1989

NASA/USRA University Advanced Design Program Fifth Annual Summer Conference

The NASA/USRA University Advanced Design Program is a unique program that brings together NASA engineers, students, and faculty from United States engineering schools by integrating current and future NASA space/aeronautics engineering design projects into the university curriculum. The Program was conceived in the fall of 1984 as a pilot project to foster engineering design education in the universities and to supplement NASA's in-house efforts in advanced planning for space and aeronautics design. Nine universities and five NASA centers participated in the first year of the pilot project. Close cooperation between the NASA centers and the universities, the careful selection of design topics, and the enthusiasm of the students has resulted in a very successful program than now includes forty universities and eight NASA centers. The study topics cover a broad range of potential space and aeronautics projects which could be undertaken during a 20-30 year period beginning with the deployment of the Space Station Freedom scheduled for the mid1990s. Both manned and unmanned endeavors are embraced, and the systems approach to the design problem is emphasized. The student teams pursue the chosen problem during their senior year in a one or two semester capstone design course and submit a comprehensive written report at the conclusion of the project. Finally, student representatives from each of the universities summarize their work in oral presentations at the annual Summer Conference, held at one of the NASA centers and attended by the university faculty, NASA and USRA personnel, and aerospace industry representatives.

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NASA NTRS1989

Lunar base and Mars base design projects

The space design classes at the University of Texas at Austin undertook seven projects in support of the NASA/USRA advanced space design program during the 1988-89 year. A total of 51 students, including 5 graduate students, participated in the design efforts. Four projects were done within the Aerospace Engineering (ASE) design program and three within the Mechanical Engineering (ME) program. Both lunar base and Mars base design efforts were studied, and the specific projects were as follows: Lunar Crew Emergency Rescue Vehicle (ASE); Mars Logistics Lander Convertible to a Rocket Hopper (ME); A Robotically Constructed Production and Supply Base on Phobos (ASE); A Mars/Phobos Transportation System (ASE); Manned Base Design and Related Construction Issues for Mars/Phobos Mission (ME); and Health Care Needs for a Lunar Colony and Design of Permanent Medical Facility (ME).

Amos, J.↗

NASA NTRS1990

Control/structure interaction conceptual design tool

The JPL Control/Structure Interaction Program is developing new analytical methods for designing micro-precision spacecraft with controlled structures. One of these, the Conceptual Design Tool, will illustrate innovative new approaches to the integration of multi-disciplinary analysis and design methods. The tool will be used to demonstrate homogeneity of presentation, uniform data representation across analytical methods, and integrated systems modeling. The tool differs from current 'integrated systems' that support design teams most notably in its support for the new CSI multi-disciplinary engineer. The design tool will utilize a three dimensional solid model of the spacecraft under design as the central data organization metaphor. Various analytical methods, such as finite element structural analysis, control system analysis, and mechanical configuration layout, will store and retrieve data from a hierarchical, object oriented data structure that supports assemblies of components with associated data and algorithms. In addition to managing numerical model data, the tool will assist the designer in organizing, stating, and tracking system requirements.

Briggs, Hugh C.↗

NASA NTRS1991

NASA Space Engineering Research Center for VLSI systems design

This annual review reports the center's activities and findings on very large scale integration (VLSI) systems design for 1990, including project status, financial support, publications, the NASA Space Engineering Research Center (SERC) Symposium on VLSI Design, research results, and outreach programs. Processor chips completed or under development are listed. Research results summarized include a design technique to harden complementary metal oxide semiconductors (CMOS) memory circuits against single event upset (SEU); improved circuit design procedures; and advances in computer aided design (CAD), communications, computer architectures, and reliability design. Also described is a high school teacher program that exposes teachers to the fundamentals of digital logic design.

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NASA NTRS1993

A minimum cost tolerance allocation method for rocket engines and robust rocket engine design

Rocket engine design follows three phases: systems design, parameter design, and tolerance design. Systems design and parameter design are most effectively conducted in a concurrent engineering (CE) environment that utilize methods such as Quality Function Deployment and Taguchi methods. However, tolerance allocation remains an art driven by experience, handbooks, and rules of thumb. It was desirable to develop and optimization approach to tolerancing. The case study engine was the STME gas generator cycle. The design of the major components had been completed and the functional relationship between the component tolerances and system performance had been computed using the Generic Power Balance model. The system performance nominals (thrust, MR, and Isp) and tolerances were already specified, as were an initial set of component tolerances. However, the question was whether there existed an optimal combination of tolerances that would result in the minimum cost without any degradation in system performance.

Gerth, Richard J.↗

NASA NTRS1993

Concepts and embodiment design of a reentry recumbent seating system for the NASA Space Shuttle

This report deals with the generation of a recumbent seating system which will be used by NASA to shuttle astronauts from the Russian space station Mir. We begin by examining the necessity for designing a special couch for the returning astronauts. Next, we discuss the operating conditions and constraints of the recumbent seating system and provide a detailed function structure. After working through the conceptual design process, we came up with ten alternative designs which are presented in the appendices. These designs were evaluated and weighted to systematically determine the best choice for embodiment design. A detailed discussion of all components of the selected system follows with design calculations for the seat presented in the appendices. The report concludes with an evaluation of the resulting design and recommendations for further development.

Mcmillan, Scott↗

NASA NTRS1993

Intelligent systems and advanced user interfaces for design, operation, and maintenance of command management systems

Historically, command management systems (CMS) have been large and expensive spacecraft-specific software systems that were costly to build, operate, and maintain. Current and emerging hardware, software, and user interface technologies may offer an opportunity to facilitate the initial formulation and design of a spacecraft-specific CMS as well as to develop a more generic CMS system. New technologies, in addition to a core CMS common to a range of spacecraft, may facilitate the training and enhance the efficiency of CMS operations. Current mission operations center (MOC) hardware and software include Unix workstations, the C/C++ programming languages, and an X window interface. This configuration provides the power and flexibility to support sophisticated and intelligent user interfaces that exploit state-of-the-art technologies in human-machine interaction, artificial intelligence, and software engineering. One of the goals of this research is to explore the extent to which technologies developed in the research laboratory can be productively applied in a complex system such as spacecraft command management. Initial examination of some of these issues in CMS design and operation suggests that application of technologies such as intelligent planning, case-based reasoning, human-machine systems design and analysis tools (e.g., operator and designer models), and human-computer interaction tools (e.g., graphics, visualization, and animation) may provide significant savings in the design, operation, and maintenance of the CMS for a specific spacecraft as well as continuity for CMS design and development across spacecraft. The first six months of this research saw a broad investigation by Georgia Tech researchers into the function, design, and operation of current and planned command management systems at Goddard Space Flight Center. As the first step, the researchers attempted to understand the current and anticipated horizons of command management systems at Goddard. Preliminary results are given on CMS commonalities and causes of low re-use, and methods are proposed to facilitate increased re-use.

Potter, William J.↗

NASA NTRS1994

Design and fabrication of forward-swept counterrotation blade configuration for wind tunnel testing

Work performed by GE Aircraft on advanced counterrotation blade configuration concepts for high speed turboprop system is described. Primary emphasis was placed on theoretically and experimentally evaluating the aerodynamic, aeromechanical, and acoustic performance of GE-defined counterrotating blade concepts. Several blade design concepts were considered. Feasibility studies were conducted to evaluate a forward-swept versus an aft-swept blade application and how the given blade design would affect interaction between rotors. Two blade designs were initially selected. Both designs involved in-depth aerodynamic, aeromechanical, mechanical, and acoustic analyses followed by the fabrication of forward-swept, forward rotor blade sets to be wind tunnel tested with an aft-swept, aft rotor blade set. A third blade set was later produced from a NASA design that was based on wind tunnel test results from the first two blade sets. This blade set had a stiffer outer ply material added to the original blade design, in order to reach the design point operating line. Detailed analyses, feasibility studies, and fabrication procedures for all blade sets are presented.

Nichols, G. H.↗

NASA NTRS1992

Local design optimization for composite transport fuselage crown panels

Composite transport fuselage crown panel design and manufacturing plans were optimized to have projected cost and weight savings of 18 and 45 percent, respectively. These savings are close to those quoted as overall NASA Advanced Composite Technology (ACT) program goals. Three local optimization tasks were found to influence the cost and weight of fuselage crown panels. The effects are summarized of each task and the task associated with a design cost model is described in detail. Studies were performed to evaluate the relationship between manufacturing cost and design details. A design tool was developed to aid in these studies. The development of the design tool included combining cost and performance constraints with a random search optimization algorithm. The resulting software was used in a series of optimization studies that evaluated the sensitivity of design variables, guidelines, criteria, and material selection on cost. The effect of blending adjacent design points in a full scale panel subjected to changing load distributions and local variations was shown to be important. Technical issues and directions for future work were identified.

Swanson, G. D.↗