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All sourcesNASA NTRSDOE OSTI
NASA NTRS1994

Basic principles of flight test instrumentation engineering, volume 1, issue 2

Volume 1 of the AG 300 series on ´Flight Test Instrumentation´ gives a general introduction to the basic principles of flight test instrumentation. The other volumes in the series provide more detailed treatments of selected topics on flight test instrumentation. Volume 1, first published in 1974, has been used extensively as an introduction for instrumentation courses and symposia, as well as being a reference work on the desk of most flight test and instrumentation engineers. It is hoped that this second edition, fully revised, will be used with as much enthusiasm as the first edition. In this edition a flight test system is considered to include both the data collection and data processing systems. In order to obtain an optimal data flow, the overall design of these two subsystems must be carefully matched; the detail development and the operation may have to be done by separate groups of specialists. The main emphasis is on the large automated instrumentation systems used for the initial flight testing of modern military and civil aircraft. This is done because there, many of the problems, which are discussed here, are more critical. It does not imply, however, that smaller systems with manual data processing are no longer used. In general, the systems should be designed to provide the required results at the lowest possible cost. For many tests which require only a few parameters, relatively simple systems are justified, especially if no complex equipment is available to the user. Although many of the aspects discussed in this volume apply to both small and large systems, aspects of the smaller systems are mentioned only when they are of special interest. The volume has been divided into three main parts. Part 1 defines the main starting points for the design of a flight test instrumentation system, as seen from the points of view of the flight test engineer and the instrumentation engineer. In Part 2 the discussion is concentrated on those aspects which apply to each individual measuring channel, and in Part 3 the main emphasis is on the integration of the individual data channels into one data collection system and on those aspects of the data processing which apply to the complete system.

channels (data transmission)↗
NASA NTRS1993

Space Shuttle Main Engine instrumented High Pressure Oxidizer Turbopump technology test bed testing results summary

This paper presents the test results from the Space Shuttle Main Engine (SSME) instrumented High Pressure Oxidizer Turbopump (HPOTP). The turbopump was tested on Engine 3001, a highly instrumented engine, in an effort to characterize the turbopump and the engine system. Seven tests, for a total duration of 766 seconds, were performed over a five month time period. The testing was performed at a wide variety of engine conditions. Changes in engine mixture ratio, power level, engine inlet oxidizer pressure, engine inlet fuel pressure, and engine start sequence were made. A discussion of all the HPOTP pressure and temperature data obtained are presented with comparisons to supporting analyses made where applicable. The effect of the various engine conditions on the measured data is addressed. This paper also discusses the challenges that were overcome to obtain the data. The significant instrumentation related problems encountered during the design, fabrication, and testing of this turbopump are summarized. Only those issues that affected the data obtained or the instrumentation itself are discussed. The relevance of the data to other noninstrumented turbomachinery is outlined. Conclusions and recommendations resulting from the test series will be presented.

Koelbl, Mary E.↗
NASA NTRS1992

SSME improved characterization using highly instrumented engine test data

This paper discusses the analysis of Space Shuttle Main Engine (SSME) 3001 test data and its applications to steady-state models. Engine 3001 is a highly instrumented Phase II (current configuration) SSME that was tested at the Technology Test Bed facility located at Marshall Space Flight Center. A test series covering a carefully selected range of operating conditions was performed during 1991. An analysis of pressure, temperature and flowrate data was performed to evaluate the ability of steady-state models to accurately characterize the internal system of an SSME. Much of the special instrumentation was used to acquire data never before measured at the engine level prior to Engine 3001 testing. The analysis revealed that modifications are needed to improve model calculations of internal Hydrogen and Oxygen flows. Modifying steady-state models to more accurately simulate the internal flow system of an SSME should improve both engine performance evaluations and prediction capabilities.

Piekarski, Brian↗
NASA NTRS1980

Fatigue strength testing employed for evaluation and acceptance of jet-engine instrumentation probes

This report outlines the fatigue type testing performed on instrumentation rakes and probes intended for use in the air flow passages of jet-engines during full-scale engine tests at Lewis Research Center. Included is a discussion of each type of test performed, the results that may be derived and means of inspection. A design and testing sequence outlines the procedures and considerations involved in the generation of suitable instrument probes.

Armentrout, E. C.↗
NASA NTRS1973

Optical instrumentation engineering in science, technology and society; Proceedings of the Sixteenth Annual Technical Meeting, San Mateo, Calif., October 16-18, 1972

Visual tracking performance in instrumentation is discussed together with photographic pyrometry in an aeroballistic range, optical characteristics of spherical vapor bubbles in liquids, and the automatic detection and control of surface roughness by coherent diffraction patterns. Other subjects explored are related to instruments, sensors, systems, holography, and pattern recognition. Questions of data handling are also investigated, taking into account minicomputer image storage for holographic interferometry analysis, the design of a video amplifier for a 90 MHz bandwidth, and autostereoscopic screens. Individual items are announced in this issue.

Katz, Y. H.↗
NASA NTRS1982

Modular Engine Instrumentation System

System that provides information and measurements never obtained before in real time has been developed. System shows not only real-time measurements but also results of computations of key combustion parameters in meaningful and easily understood display. Standard commercially-available shaft encoder plus data from pressure transducer act as principal drivers to device. Eventually, modular system could be developed into onboard controller for automobile engines.

Rice, W. J.↗
NASA NTRS1992

Engine component instrumentation development facility at NASA Lewis Research Center

The Engine Components Instrumentation Development Facility at NASA Lewis is a unique aeronautics facility dedicated to the development of innovative instrumentation for turbine engine component testing. Containing two separate wind tunnels, the facility is capable of simulating many flow conditions found in most turbine engine components. This facility's broad range of capabilities as well as its versatility provide an excellent location for the development of novel testing techniques. These capabilities thus allow a more efficient use of larger and more complex engine component test facilities.

Bruckner, Robert J.↗
NASA NTRS1992

Engine component instrumentation development facility at NASA Lewis Research Center

The Engine Components Instrumentation Development Facility at NASA Lewis is a unique aeronautics facility dedicated to the development of innovative instrumentation for turbine engine component testing. Containing two separate wind tunnels, the facility is capable of simulating many flow conditions found in most turbine engine components. This facility's broad range of capabilities as well as its versatility provide an excellent location for the development of novel testing techniques. These capabilities thus allow a more efficient use of larger and more complex engine component test facilities.

Bruckner, Robert J.↗
NASA NTRS1994

Cometary Coma Chemical Composition (C4) Mission

Cometary exploration remains of great importance to virtually all of space science. Because comets are presumed to be remnants of the early solar nebula, they are expected to provide fundamental knowledge as to the origin and development of the solar system as well as to be key to understanding of the source of volatiles and even life itself in the inner solar system. Clearly the time for a detailed study of the composition of these apparent messages from the past has come. A comet rendezvous mission, the Cometary Coma Chemical Composition (C4) Mission, is now being studied as a candidate for the new Discovery program. This mission is a highly-focussed and usefully-limited subset of the Cometary Rendezvous Asteroid Flyby (CRAF) Mission. The C4 mission will concentrate on measurements that will produce an understanding of the composition and physical makeup of a cometary nucleus. The core science goals of the C4 mission are 1) to determine the chemical, elemental, and isotopic composition of a cometary nucleus and 2) to characterize the chemical and isotopic nature of its atmosphere. A related goal is to obtain temporal information about the development of the cometary coma as a function of time and orbital position. The four short-period comets -- Tempel 1, Tempel 2, Churyumov-Gerasimenko, and Wirtanen -which all appear to have acceptable dust production rates, were identified as candidate targets. Mission opportunities have been identified beginning as early as 1998. Tempel I with a launch in 1999, however, remains the baseline comet for studies of and planning the C4 mission. The C4 mission incorporates two science instruments and two engineering instruments in the payload to obtain the desired measurements. The science instruments include an advanced version of the Cometary Ice and Dust Experiment (CIDEX), a mini-CIDEX with a sample collection system, an X-ray Fluorescence Spectrometer and a Pyrolysis-Gas Chromatograph, and a simplified version of the Neutral Gas and Ion Mass Spectrometer (NIGMS). Both of these instruments have substantial heritage as they are based on those developed for the CRAF Mission. The engineering instruments include a simplified Comet Dust Environmental Monitor (SCODEM) and a navigational Camera, NAVCAM. While neither of the instruments will be permitted to establish science requirements, it is anticipated that significant science return will be accomplished Radio science will also be included.

Carle, Glenn C.↗
NASA NTRS1992

Demonstrated survivability of a high temperature optical fiber cable on a 1500 pound thrust rocket chamber

A demonstration of the ability of an existing optical fiber cable to survive the harsh environment of a rocket engine was performed at the NASA Lewis Research Center. The intent of this demonstration was to prove the feasibility of applying fiber optic technology to rocket engine instrumentation systems. Extreme thermal transient tests were achieved by wrapping a high temperature optical fiber, which was cablized for mechanical robustness, around the combustion chamber outside wall of a 1500 lb Hydrogen-Oxygen rocket engine. Additionally, the fiber was wrapped around coolant inlet pipes which were subject to near liquid hydrogen temperatures. Light from an LED was sent through the multimode fiber, and output power was monitored as a function of time while the engine was fired. The fiber showed no mechanical damage after 419 firings during which it was subject to transients from 30 K to 350 K, and total exposure time to near liquid hydrogen temperatures in excess of 990 seconds. These extreme temperatures did cause attenuation greater than 3 dB, but the signal was fully recovered at room temperature. This experiment demonstrates that commercially available optical fiber cables can survive the environment seen by a typical rocket engine instrumentation system, and disclose a temperature-dependent attenuation observed during exposure to near liquid hydrogen temperatures.

Sovie, Amy L.↗
NASA NTRS1991

Infusion of instrumentation technology (engine plume diagnostics) into operational test programs

The following subject areas are covered: hierarchy of civil space technology program; evolution of technology development; technology validation process; potential impacts; impacts of technology infusion into flight certifications; potential solutions; examples of current technology infusion into flight certification; OAET-CSTI health monitoring and controls; and challenges for future space vehicle propulsion systems.

Woods, E. G.↗
NASA NTRS1987

Challenges in modeling the X-29 flight test performance

Presented are methods, instrumentation, and difficulties associated with drag measurement of the X-29A aircraft. The initial performance objective of the X-29A program emphasized drag polar shapes rather than absolute drag levels. Priorities during the flight envelope expansion restricted the evaluation of aircraft performance. Changes in aircraft configuration, uncertainties in angle-of-attack calibration, and limitations in instrumentation complicated the analysis. Limited engine instrumentation with uncertainties in overall in-flight thrust accuracy made it difficult to obtain reliable values of coefficient of parasite drag. The aircraft was incapable of tracking the automatic camber control trim schedule for optimum wing flaperon deflection during typical dynamic performance maneuvers; this has also complicated the drag polar shape modeling. The X-29A was far enough off the schedule that the developed trim drag correction procedure has proven inadequate. However, good drag polar shapes have been developed throughout the flight envelope. Preliminary flight results have compared well with wind tunnel predictions. A more comprehensive analysis must be done to complete performance models. The detailed flight performance program with a calibrated engine will benefit from the experience gained during this preliminary performance phase.

John W Hicks↗
NASA NTRS1987

Challenges in modeling the X-29A flight test performance

The paper presents the methods, instrumentation, and difficulties associated with drag measurement of the X-29A aircraft. The initial performance objective of the X-29A program emphasized drag polar shapes rather than absolute drag levels. Priorities during the flight envelope expansion restricted the evaluation of aircraft performance. Changes in aircraft configuration, uncertainties in angle-of-attack calibration, and limitations in instrumentation complicated the analysis. Limited engine instrumentation with uncertainties in overall in-flight thrust accuracy made it difficult to obtain reliable values of coefficient of parasite drag. The aircraft was incapable of tracking the automatic camber control trim schedule for optimum wing flaperon deflection during typical dynamic performance maneuvers; this has also complicated the drag polar shape modeling. The X-29A was far enough off the schedule that the developed trim drag correction procedure has proven inadequate. Despite these obstacles, good drag polar shapes have been developed throughout the flight envelope. Preliminary flight results have compared well with wind tunnel predictions. A more comprehensive analysis must be done to complete the performance models. The detailed flight performance program with a calibrated engine will benefit from the experience gained during this preliminary performance phase.

Hicks, John W.↗
NASA NTRS1993

STS-55 pad abort: Engine 2011 oxidizer preburner augmented spark igniter check valve leak

The STS-55 initial launch attempt of Columbia (OV102) was terminated on KSC launch pad A March 22, 1993 at 9:51 AM E.S.T. due to violation of an ME-3 (Engine 2011) Launch Commit Criteria (LCC) limit exceedance. The event description and timeline are summarized. Propellant loading was initiated on 22 March, 1993 at 1:15 AM EST. All SSME chill parameters and launch commit criteria (LCC) were nominal. At engine start plus 1.44 seconds, a Failure Identification (FID) was posted against Engine 2011 for exceeding the 50 psia Oxidizer Preburner (OPB) purge pressure redline. The engine was shut down at 1.50 seconds followed by Engines 2034 and 2030. All shut down sequences were nominal and the mission was safely aborted. The OPB purge pressure redline violation and the abort profile/overlay for all three engines are depicted. SSME Avionics hardware and software performed nominally during the incident. A review of vehicle data table (VDT) data and controller software logic revealed no failure indications other than the single FID 013-414, OPB purge pressure redline exceeded. Software logic was executed according to requirements and there was no anomalous controller software operation. Immediately following the abort, a Rocketdyne/NASA failure investigation team was assembled. The team successfully isolated the failure cause to the oxidizer preburner augmented spark igniter purge check valve not being fully closed due to contamination. The source of the contaminant was traced to a cut segment from a rubber O-ring which was used in a fine clean tool during valve production prior to 1992. The valve was apparently contaminated during its fabrication in 1985. The valve had performed acceptably on four previous flights of the engine, and SSME flight history shows 780 combined check valve flights without failure. The failure of an Engine 3 (SSME No. 2011) check valve to close was sensed by onboard engine instruments even though all other engine operations were normal. This resulted in an engine shutdown and safe sequential shutdown of all three engines prior to ignition of the solid boosters.

Source record↗
NASA NTRS1982

The JT9D Jet Engine Diagnostics Program

The various engine deterioration phenomena that affect JT9D performance retention were studied, and approaches to improve performance retention of engines were identified. The program included surveys of historical data, monitoring of in service engines, ground and flight testing of instrumented engines, analysis, and analytical modeling. Performance deterioration is made up of both short and long term modes, both of which are flight cycle related phenomena. Short term deterioration occurs primarily during airplane acceptance testing prior to delivery to the airline. This effect is caused by flight load and power induced clearance closures and engine deflections with resulting rubbing of airfoils and seals. Long term deterioration is caused by erosion of airfoils and gas path seals during ground operation and take off and by cyclic induced thermal distortion of the high pressure turbine airfoils. Studies of possible remedial approaches have shown that performance retention within 1 to 2 percent of initial revenue service performance can be achieved with a proper program of hot section and cold section maintenance.

Olsson, W. J.↗