Space vehicle production and attendant requirements
Management techniques to maintain quality, cost control, and production schedules in manufacture of space vehicle end products
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Summary of Flight-Test Results of the VZ-2 Tilt-Wing Aircraft
Flight-test information gained from a tilt-wing research aircraft tested at the Langley Research Center has shown that design problems exist in such fields as low-speed stability and control, handling qualities, and flow separation during transition. The control power in the near-hovering configuration was considered by the pilots to be inadequate in yaw, marginal in pitch, and excessive in roll. Solutions for some of the design problems are indicated; for example, the addition of a leading-edge droop to the wing in an attempt to delay flow separation resulted in such significantly improved handling qualities in the transition range that an additional descent capability of 1,100 feet per minute was obtained.
Pegg, Robert J.↗
Trial by Fire
The NASa/ATK Thiokol space shuttle solid rocket motor program has doubled ground test firings and enhanced manufacturing quality and process control to increase safety for Discovery's return to flight. There are a number of places where we've strengthened our engineering and our processes, says Mike Kahn, ATK Thiokol vice president of space launch systems. Protecting the booster against corrosion in the humid Florida environment is one area that has been addressed. Since the loss of Columbia, ATK Thiokol and the Marshall Space Flight Center have completely reevaluated the shuttle solid rocket motor's design certification and found no major problems, Kahn said. The Thiokol solid motors did not play a role in the 2003 Columbia accident, but the motor's older field joint design (since replaced) was the primary cause of the 1986 Challenger accident that killed seven astronauts. The 129 X 12-ft. ATK Thiokol reusable solid rocket motor forms the core of the shuttle's two solid rocket boosters (SRBs). United Space Alliance (USA) has overall responsibility for the booster's nose-mounted systems such as recovery parachutes and aft-mounted thrust vector control systems that increase the length to 149 ft. USA and its subcontractors have also reaffirmed quality control on systems such as the booster's Hamilton Sundstrand hydraulic power units for critical thrust vector control. And to ensure greater safeguards against booster debris jeopardizing the orbiter, a bolt-catcher system to restrain the large bolts, severed at booster separation, was also redesigned.
Covault, Craig↗
Experimental evaluation of the concept of supevisory manipulation
A computer-controlled teleoperator system which is based on task-referenced sensor-aided control has been developed to study supervisory manipulation. This system, called SUPERMAN, is capable of performing complicated tasks in real-time by utilizing the operator for high-level functions related to the unpredictable portions of a task, while the subordinate machine performs the more well-defined subtasks under human supervison. To determine whether supervisory control schemes such as these offer any advantage over manual control under real-time conditions, a number of experiments involving both simple and complicated tasks were performed. Six representative tasks were chosen for the study: (1) obtaining a tool from a rack, (2) returning the tool to the rack, (3) removing a nut, (4) placing samples in a storage bin, (5) opening and closing a valve, and (6) digging with a shovel. The experiments were performed under simulated conditions using four forms of manual control (i.e., switch rate, joystick rate, master-slave position control, and master-slave with force feedback), as well as supervisory control. Through these experiments the effectiveness and quality of control were evaluated on the basis of the time required to complete each portion of the task and the type and number of errors which occurred.
Brooks, T. L.↗
Effect of Control System Augmentation on Handling Qualities and Task Performance in Good and Degraded Visual Environments
In June 2013, NASA and the U.S. Army jointly conducted a simulation experiment in the NASA-Ames Vertical Motion Simulator that examined and quantified the effects of limited-authority control system augmentation on handling qualities and task performance in both good and degraded visual environments (DVEs). The vehicle model used for the experiment was the OH-58D with similar size, weight and performance, and the same 4-blade rotor system as the Bell 407 civilian helicopter that is commonly used for medical evacuation and emergency medical services. The control systems investigated as part of this study included the baseline aircraft Rate Command system, a short-term Attitude Command/Attitude Hold system that uses lagged-rate feedback to provide a short-term attitude response, Modernized Control Laws that provide an Attitude Command/Attitude Hold control response type, and Modernized Control Laws with an additional Position Hold function. Evaluation tasks included the ADS-33 Hover, Sidestep, Acceleration/Deceleration, and Pirouette Mission Task Elements, as well as a new proposed Emergency Medical Services task that includes an approach and landing at a minimally prepared remote landing site. Degraded visual environments were simulated with night vision goggles and an unaided night scene. A total of nine experimental test pilots participated in the four-week simulation experiment. Data recorded during the evaluation included Cooper-Harper handling qualities ratings, Bedford Workload scale ratings, and task performance. The Usable Cue Environment (UCE) was measured for this simulation experiment, and found to be UCE equals 1 in good visual environments and UCE equals 2 in degraded visual environments with night vision goggles. Results showed that handling qualities ratings were improved with a control system providing short-term attitude response over a rate command system, although the improvements were not sufficient to produce Level 1 handling qualities in degraded visual environments. Results for an Attitude Command/Attitude Hold control system showed that borderline Level 1 handling qualities could be achieved in degraded visual environments, and the 10 percent authority stability augmentation system was adequate to obtain these handling qualities ratings.
Handling Qualities↗
Water Quality Contamination Sources and Controls for the Exploration Extra-vehicular Mobility Unit (xEMU)
NASA has been developing a new spacesuit, called the Exploration Extravehicular Mobility Unit (xEMU) for over a decade. This spacesuit is underdevelopment to support missions to the International Space Station (ISS) and also to the Moon. The xEMU uses controlled evaporative cooling through a membrane to reject waste heat from the crewmember, avionics, and environmental in-leak during autonomous operation. Given the unique mass and volume constraints imposed by the spacesuit application and the opportunities presented by the selection of a given membrane, the xEMU does not possess a separate feedwater loop to feed the evaporation process, rather the feedwater for the evaporation process is fed directly from the transport loop which collects heat from the sources within the suit. This has many benefits including mass/volume reductions from a lower component count within the system but does pose some additional potential constraints on water quality within the system in order to provide a working fluid that can be pumped, filtered, and used in contact with the remainder of the system while both avoiding fouling of the membrane as well as other deleterious effects such as creating conditions for corrosion of wetted surfaces within the transport loop. The discussion will seek to address the main sources of contamination and the applied controls. Sources considered will include: self-generated via materials selection and processes applied, influent working fluid, contamination of the influent working fluid via Ground Support Equipment (GSE) or processing equipment, microbial activity, and environmental influences such as elevated ambient CO2.
Colin Campbell↗
A Control Law Design Method Facilitating Control Power, Robustness, Agility, and Flying Qualities Tradeoffs: CRAFT
A multi-input, multi-output control law design methodology, named "CRAFT", is presented. CRAFT stands for the design objectives addressed, namely, Control power, Robustness, Agility, and Flying Qualities Tradeoffs. The methodology makes use of control law design metrics from each of the four design objective areas. It combines eigenspace assignment, which allows for direct specification of eigenvalues and eigenvectors, with a graphical approach for representing the metrics that captures numerous design goals in one composite illustration. Sensitivity of the metrics to eigenspace choice is clearly displayed, enabling the designer to assess the cost of design tradeoffs. This approach enhances the designer's ability to make informed design tradeoffs and to reach effective final designs. An example of the CRAFT methodology applied to an advanced experimental fighter and discussion of associated design issues are provided.
Murphy, Patrick C.↗
LANDSAT-1 data as it has been applied for land use and water quality data by the Virginia State Water Control Board. 1: The state project. 2: Monitoring water quality from LANDSAT
LANDSAT-1 imagery has been used for water quality and land use monitoring in and around the Swift Creek and Lake Chesdin Reservoirs in Virginia. This has proved useful by (1) helping determine valid reservoir sampling stations, (2) monitoring areas not accessible by land or water, (3) giving the State a viable means of measuring Secchi depth readings in these inaccessible areas, (4) giving an overview of trends in changing sedimentation loadings over a given time period and classifying these waters into various categories, (5) enabling the State to inventory all major lakes and reservoirs and computing their acreage, (6) monitoring land use changes in any specific area, (7) evaluating possible long-term environmental effects of nearby developments, and (8) monitoring and predicting population shifts with possible impact on water quality problems. The main problems in the long-term use of such imagery appear to be cost and lack of consistency due to cloud cover limitations.
Trexler, P. L.↗
A design procedure and handling quality criteria for lateral directional flight control systems
A practical design procedure for aircraft augmentation systems is described based on quadratic optimal control technology and handling-quality-oriented cost functionals. The procedure is applied to the design of a lateral-directional control system for the F4C aircraft. The design criteria, design procedure, and final control system are validated with a program of formal pilot evaluation experiments.
Stein, G.↗
Simulator investigations of various control systems for VTOL aircraft
Six-degree-of-freedom motion simulator study of handling qualities and control system power requirements for VTOL aircraft
CONTROL SYSTEM↗
Rotorcraft system identification techniques for handling qualities and stability and control evaluation
An integrated approach to rotorcraft system identification is described. This approach consists of sequential application of (1) data filtering to estimate states of the system and sensor errors, (2) model structure estimation to isolate significant model effects, and (3) parameter identification to quantify the coefficient of the model. An input design algorithm is described which can be used to design control inputs which maximize parameter estimation accuracy. Details of each aspect of the rotorcraft identification approach are given. Examples of both simulated and actual flight data processing are given to illustrate each phase of processing. The procedure is shown to provide means of calibrating sensor errors in flight data, quantifying high order state variable models from the flight data, and consequently computing related stability and control design models.
Hall, W. E., Jr.↗
The interpretation of flying qualities requirements for flight control design
The flying requirements of MIL-F-8785(C) are interpreted in terms of command/response configurations, and pilot preference for flight control systems configurations of angle of attack, or pitch rate command, specified independently for the short period and phugoid dynamics, is determined using the Total-In-Flight-Simulator aircraft. The results show that for either command configuration, the short term response applies to the angle of attack response of the vehicle, and that this response must satisfy the omega(n) vs n/alpha requirement. The preference in the long term for angle of attack command indicates that the pilot wants the aircraft to fly in the direction it is pointing, and an attitude hold system is not found to be preferred unless attitude hold results in flight path angle hold.
Rynaski, E. G.↗
(abstract) Mission Operations and Control Assurance: Flight Operations Quality Improvements
Mission Operations and Command Assurance (MO&CA), a recent addition to flight operations teams at JPL. provides a system level function to instill quality in mission operations. MO&CA's primary goal at JPL is to help improve the operational reliability for projects during flight. MO&CA tasks include early detection and correction of process design and procedural deficiencies within projects. Early detection and correction are essential during development of operational procedures and training of operational teams. MO&CA's effort focuses directly on reducing the probability of radiating incorrect commands to a spacecraft. Over the last seven years at JPL, MO&CA has become a valuable asset to JPL flight projects. JPL flight projects have benefited significantly from MO&CA's efforts to contain risk and prevent rather than rework errors. MO&CA's ability to provide direct transfer of knowledge allows new projects to benefit directly from previous and ongoing experience. Since MO&CA, like Total Quality Management (TQM), focuses on continuous improvement of processes and elimination of rework, we recommend that this effort be continued on NASA flight projects.
mission operation flight operations error detectio↗
Nonlinear programming in design of control systems with specified handling qualities.
A method is described for using nonlinear programing in the computer-aided design of aircraft control systems. It is assumed that the quality of such systems depends on many criteria. These criteria are included in the constraints vector, and the design proceeds through a sequence of nonlinear programing solutions in which the designer varies the specification of sets of requirements levels. The method is applied to design of a lateral stability augmentation system (SAS) for a fighter aircraft, in which the requirements vector is chosen from the official handling-qualities specifications. Results are shown for several simple SAS configurations designed to obtain desirable handling qualities over all design flight conditions with minimum feedback gains.
Schy, A. A.↗
Piloted simulator investigation of helicopter control systems effects on handling qualities during instrument flight
An exploratory piloted simulation was conducted to investigate the effects of the characteristics of helicopter flight control systems on instrument flight handling qualities. This joint FAA/NASA study was motivated by the need to improve instrument flight capability. A near-term objective is to assist in updating the airworthiness criteria for helicopter instrument flight. The experiment consisted of variations of single-rotor helicopter types and levels of stability and control augmentation systems (SCAS). These configurations were evaluated during an omnirange approach task under visual and instrument flight conditions. The levels of SCAS design included a simple rate damping system, collective decoupling plus rate damping, and an attitude command system with collective decoupling. A limited evaluation of stick force versus airspeed stability was accomplished. Some problems were experienced with control system mechanization which had a detrimental effect on longitudinal stability. Pilot ratings, pilot commentary, and performance data related to the task are presented.
Forrest, R. D.↗
Multitarget control models for building thermal comfort and indoor air quality - A critical review
The control techniques in buildings contribute significantly to thermal comfort and indoor air quality (IAQ). However, the gaps are existing for multitarget controls considering both thermal comfort and IAQ. They are: (1) both experimental and modeling control studies were conducted for thermal comfort, focusing on temperature and humidity. (2) All three (physical, grey-box, black-box) modeling approaches were investigated for temperature control. (3) Physical and grey-box modeling approach were adopted for humidity control. (4) physical models were developed for VOCs and CO2 control. (5) grey-box and black-box models were lacking for VOCs and CO2. (6) Multi-target controls were lacking for temperature, humidity and CO2s. (7) Limited studies are available for multi-target controls for temperature, humidity, and VOCs. (8) Multi-target controls are not available yet for temperature, humidity, VOCs, and CO2.
42 ENGINEERING↗
Handling qualities of large flexible control-configured aircraft
The approach to an analytical study of flexible airplane longitudinal handling qualities was to parametrically vary the natural frequencies of two symmetric elastic modes to induce mode interactions with the rigid body dynamics. Since the structure of the pilot model was unknown for such dynamic interactions, the optimal control pilot modeling method is being applied and used in conjunction with pilot rating method.
Swaim, R. L.↗
Laboratory-Scale Coal-Derived Graphene Process (Final Report)
The Energy & Environmental Research Center (EERC) conducted a laboratory-scale coal-derived graphene (CDG) project focused on developing a technological process for making graphene from four U.S. domestic coal or coal wastes, including lignite from North Dakota, subbituminous coal from Wyoming, bituminous coal from Utah, and anthracite from Pennsylvania. The project was divided into two performance or budget periods (BPs), with BP1 comprising the up-front laboratory experiments to make graphene materials from coal beginning on May 1, 2020, to April 30, 2022. BP2 was conducted from May 1, 2022, to April 30, 2023, and was focused on analyzing the CDG process economic feasibility and the technical gaps for technological scale-up and commercialization. During this project, a few different coal-derived high-value products have been demonstrated, including graphite, graphene oxide (GO), reduced graphene oxide (rGO), and graphene quantum dots (GQDs). A new graphite microstructure was discovered and named “croissant graphite” because of the exterior morphological and textural resemblance to croissant food items sold in commercial groceries stores. The new graphite structure and the associated preparation from coal or coal waste feedstocks has been the subject of a U.S. patent application. The systematic experimental processes involving coal cleaning, upgrading, and conversion to high-value carbon products culminated into a developed upgraded coal-to-products (UCP) technology that is being pursued for potential fast-track commercialization, if funding is available. It is envisioned that commercialization of the UCP technology would increase consumption of U.S. domestic coals or coal wastes to make environmentally sustainable high-value products for the electronics industry, high-energy-storage applications, and clean energy technologies such as electric vehicle (EV) lithium-ion batteries (LIBs), for which graphite has become a critical mineral commodity. Croissant graphite microstructures, when observed by field emission scanning electron microscopy (FESEM), display wavy surface morphology and often grow from a base that is made of graphitized particles with honeycomb-like layers, which are believed to be graphene layers. While more studies are needed to fully ascertain the mechanisms of the croissant graphite microstructure formation, it is postulated that their growth may begin from curling of the graphene sheets into ribbon-like structures, and continuous growth and densification of the ribbon-like structures forms croissant microstructures. Additional studies are ongoing to evaluate the electrochemical performance of croissant graphite for LIB applications and to determine the experimental conditions necessary to tune on/off croissant formation so that it can be either optimized or suppressed depending on performance evaluation results. In addition to the discovery of croissant graphite, the graphitization process from the four coal ranks in general was successful. X-ray diffraction (XRD) analysis showed that the degree of graphitization (DoG) ranged from 12% to 80% in an early sample set, and further optimization on lignite coal produces a DoG of about 92%, which was spectacular to see as lignite is the lowest-rank coal. Thus, it is expected that the graphitization performance for higher-rank coals will be similar or better when optimized as well. The coal-derived graphite was used to make GO and rGO. Analytical characterization, e.g., by methods such as Raman spectroscopy, XRD, Fourier transform infrared (FTIR) spectroscopy and FESEM, showed that the sequence of converting the coal to graphite, exfoliating it to GO, and then chemically reducing the GO to rGO was successful. Although coal naturally contains aromatic compounds and some relatively small-sized condensed aromatic units, it does not contain graphene sheets. In the UCP process, the aromatic domains in the coals, particularly low-rank coals, are concentrated and condensed further into graphene sheets, which are ordered into a 3D stack during graphitization. The synthesized graphite is then unpacked by methods such as exfoliation to various graphene products. GQDs were synthesized from all four coal types, and their optical properties were demonstrated to be tunable by the coal precursor preprocessing treatments. In all four coal types, enhanced optical properties were observed for the produced GDQs with incremental improvements made to the coal precursors. GQDs produced from raw coal samples displayed lower ultraviolet–visible (UV–Vis) spectroscopy absorbance intensity compared to those obtained from cleaned and upgraded coal residues. The photoluminescence (PL) intensities also varied with pretreatment conditions and with the concentration of GQDs in aqueous solutions. GQDs obtained from anthracite show longer emission wavelengths and can be excited by visible light as opposed to GQDs derived from the other coal ranks. UV fluorescence 3D maps and spectra revealed that the emission wavelength at which the GQDs solutions display the highest intensity was slightly redshifted based on the coal precursor pretreatments. In low-rank coal (lignite and subbituminous) samples, two clusters were observed in the maps for GQDs, which may suggest that there are potentially two types of fluorophores in solution or two main size populations. The ability to tune the properties of GQDs based on processing methods can be exploited to make GQDs for various optical display or optoelectronics applications. The results also highlight the importance of removing coal-borne impurities to improve the quality of the coal precursor for preparation of graphene products. Coal and/or coal wastes preprocessing methods were developed and applied to clean and upgrade the coal precursors prior to graphitization and subsequent conversion to graphene products. The preprocessing methods involve high specific-gravity separations, mineral acid cleaning (no hydrofluoric acid), and subsequent upgrading by reducing the coal-borne heteroatom (nitrogen, sulfur, and oxygen) content using proprietary chemical agents. Analytical characterization revealed that the preprocessing steps were successful, with ash reductions that range from 38% to 80% and residual ash content that was below the 5 wt% initial target. Based on proximate and ultimate analysis, the heteroatom reduction reactions produced upgraded coal residues with the oxygen content reduced by 8% to 24%, with additional reductions in the nitrogen and sulfur contents. An initial assessment of the waste streams from the UCP process shows very small to negligible environmental impact due to CO 2 , NO x , and SO x because most process steps are performed under inert atmosphere with argon. Consequently, reactive oxygen environments that tend to create these species are avoided. The inorganic and potentially hazardous species are released into aqueous waste streams that are easy to handle for proper disposal. The liquid waste streams were found to contain low-level concentrations of rare-earth elements (REEs), which could be concentrated and recovered as value-added by-products. Additionally, the volatile and gaseous fractions from carbonization and heat treatment contain useful organic compounds that can also be recovered as potential valuable by-products. Thus, the UCP technology is considered an environmentally sustainable and promising emerging technology for making high-value products from coal and coal wastes, with potential additional value-added by-products. Analysis of potential markets for the coal-derived carbon products shows a strong demand in both niche market sectors and across a wide variety of other industrial sectors. Graphite is currently considered a critical mineral commodity that has a large and growing demand in the LIB industry for EV applications. Based on data from Fortune Business Insights (2022) and Marketwatch (2023) reports, the average global graphite market is projected to reach about 33 billion by 2028, growing at a compound annual growth rate (CAGR) of about 7%, with much of this growth expected to be in the LIB industry. GO and rGO have strong market potentials in various application areas, such as coatings for anticorrosion, anti-icing, and antimicrobial protection, thermal barriers, wear resistance, sensors, additive manufacturing such as 3D inks, and others. GQDs are the emerging key player in the bioimaging, photovoltaics, and light-emitting diodes (LEDs) applications, with the potential to replace traditional semiconductor quantum dots (SQDs), which are based on metallic systems that are more toxic and more expensive. Biomedical applications of GQDs are becoming more attractive because of low to no toxicity and extremely low cost compared to SQDs. The major challenges for scale-up and commercialization of coal-derived carbon products such as graphene vary from the inherent attributes of graphene itself to reluctance to accept graphene in new manufacturing processes because of the uncertainty of the unknown. The 2D nature of graphene materials with a thickness of one atom presents significant challenges to proper handling/processing, and process scale-up becomes difficult because it requires high-end, expensive equipment, even for routine handling and analysis for quality assurance and control. Pristine graphene can also be extremely difficult to work into other matrices, thus hindering downstream processibility, especially at large scale. Currently, the cost of graphene and graphene products is still high and presents an economic risk that tends to slow down investment in scaling up emerging technologies. The lack of a standard for graphene materials for quality assurance and quality control poses a great challenge not only for the markets but also for commercialization efforts. A first-look economic feasibility analysis of the UCP technology provided valuable information that suggests the UCP process would be feasible, especially when it is scaled to a pilot scale and could be more competitive at the full scale. Graphitization was found to be the most energy-consuming and most capital-intensive step in the overall process. In small laboratory- and bench-scale experiments, labor is a significant contributor to the total process costs. Although these energy, capital, and labor constraints contribute to a higher selling price for the product, a preliminary economic model suggests that the process would be feasible at large scale when the process is fully integrated, optimized, and automated.
01 COAL, LIGNITE, AND PEAT↗