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One of the elements of the Space Station Freedom power system is the Photovoltaic (PV) module. These modules will be assembled on-orbit during the assembly phase of the program. These modules will be assembled either from the shuttle orbiter or from the Mobile Servicing Center (MSC). The different types of assembly operations that will be used to assemble PV Modules are described.
One of the elements of the Space Station Freedom power system is the photovoltaic (PV) module. These modules will be assembled on-orbit during the assembly phase of the program. These modules will be assembled either from the Shuttle Orbiter or from the Mobile Servicing Center (MSC). The different types of assembly operations that will be used to assemble PV modules are described.
Environmental control of Apollo applications program orbital assembly, analyzing thermal and life support systems
In Project SKYLAB, the Command and Service Module which ferries astronaut crews to and from the Orbital Workshop is required to have the capability of providing attitude control for the entire Orbital Assembly during docked phases of the mission. A digital autopilot has been designed which meets this requirement. It is a direct descendant of the digital autopilot designed for and used extensively in project Apollo. There is a major difference however. For Apollo, it was reasonable to design an autopilot that treated the roll, pitch, and yaw axes independently. Because of the geometry of the Orbital Assembly, however, it is of considerable advantage to design the jet selection logic for SKYLAB such that the roll and pitch axes are treated as coupled, and also that the roll and yaw axes are treated as coupled. This paper discusses how inter-axis dependence has been incorporated in the Command and Service Module's digital autopilot while working within the limitations of the onboard computer.
While the practice of construction has a long history, the underlying theory of construction is relatively young. Very little has been documented as to techniques of logistic support, construction planning, construction scheduling, construction testing, and inspection. The lack of 'systems approaches' to construction processes is certainly one of the most serious roadblocks to the construction of space structures. System engineering research efforts at CSC are aimed at developing concepts and tools which contribute to a systems theory of space construction. The research is also aimed at providing means for trade-offs of design parameters for other research areas in CSC. Systems engineering activity at CSC has divided space construction into the areas of orbital assembly, lunar base construction, interplanetary transport vehicle construction, and Mars base construction. A brief summary of recent results is given. Several models for 'launch-on-time' were developed. Launch-on-time is a critical concept to the assembly of such Earth-orbiting structures as the Space Station Freedom, and to planetary orbiters such as the Mars transfer vehicle. CSC has developed a launch vehicle selection model which uses linear programming to find optimal combinations of launch vehicles of various sizes (Atlas, Titan, Shuttles, HLLV's) to support SEI missions. Recently, the Center developed a cost trade-off model for studying on orbit assembly logistics. With this model it was determined that the most effective size of the HLLV would be in the range of 120 to 200 metric tons to LEO, which is consistent with the choices of General Stafford's Synthesis Group Report. A second-generation Dynamic Construction Activities Model ('DYCAM') process model has been under development, based on our past results in interruptability and our initial DYCAM model. This second-generation model is built on the paradigm of knowledge-based expert systems. It is aimed at providing answers to two questions: (1) what are some necessary or sufficient conditions for judging conceptual designs of spacecraft?, and (2) can a methodology be formulated such that these conditions may be used to provide computer-aided tools for evaluating conceptual designs and planning for space assembly sequences? Early simulation results indicate that the DYCAM model has a clear ability to emulate and simulate human orbital construction processes.
In the future, some spacecraft will be so large that they must be assembled on-orbit. These spacecraft will be used for such tasks as manned missions to Mars or used as orbiting platforms for monitoring the Earth or observing the universe. Some large spacecraft will probably consist of planar truss structures to which will be attached special purpose, self-contained modules. The modules will most likely be taken to orbit fully outfitted and ready for use in heavy-lift launch vehicles. The truss members will also similarly be taken to orbit, but most unassembled. The truss structures will need to be assembled robotically because of the high costs and risks of extra-vehicular activities. Some missions will involve very large loads. To date, very few structures of any kind have been constructed in space. Two relatively simple trusses were assembled in the Space Shuttle bay in late 1985. Here the development of a design of a welded joint for on-orbit, robotic truss assembly is described. Mechanical joints for this application have been considered previously. Welded joints have the advantage of allowing the truss members to carry fluids for active cooling or other purposes. In addition, welded joints can be made more efficient structurally than mechanical joints. Also, welded joints require little maintenance (will not shake loose), and have no slop which would cause the structure to shudder under load reversal. The disadvantages of welded joints are that a more sophisticated assembly robot is required, weld flaws may be difficult to detect on-orbit, the welding process is hazardous, and welding introduces contamination to the environment. In addition, welded joints provide less structural damping than do mechanical joints. Welding on-orbit was first investigated aboard a Soyuz-6 mission in 1969 and then during a Skylab electron beam welding experiment in 1973. A hand held electron beam welding apparatus is currently being prepared for use on the MIR space station. Presently, Marshall Space Flight Center is evaluating processes appropriate for on-orbit welding. A low gravity environment has been found to have very minor effects on the welding processes appropriate for this application. This is based on tests run on-orbit as well as low gravity environments achieved by flying aircraft in parabolic trajectories. It appears that a modified form of gas tungsten arc welding (GTAW) will be most appropriate for welding together structures on-oribt. The process has been modified to work in a vacuum by providing gas to the arc zone by means of a hollow tungsten electrode with special shielding. A commercial tube welding head has been successfully modified for use on-orbit with a gas leakage rate of approximately 2.5 liters/min. To develop as realistic a joint as possible, a specific truss structure was selected on which to base the design. The structure considered was based on the 120 foot diameter aerobrake tetrahedral truss structure. The truss members were assumed to consist of graphite/epoxy tubes. Also, it was assumed that the nodes were constructed of 2219-T87 aluminum alloy. The magnitude of the member load assumed for design purposes was 100 kips.
McDonnell Douglas Space Systems Company at Kennedy Space Center (MDSSC-KSC) has been tasked since November 1987 to provide support to the Space Station Evolution Working Group (EWG) based at NASA's Langley Research Center (LaRC). Work in the first year of this study included extensive data gathering and the development of study methodologies. The OEXP case studies as summarized in NASA Technical Memorandum 4075, Exploration Studies Technical Report FY 1988 Status, and NASA Document Z-2.1-002, Study Requirements Document FY 1989 Studies (SRD), define the mission scenarios and technical requirements which MSFC engineers and their contractors (Martin Marietta and Boeing) utilized in their design of exploration vehicles. LaRC selected case studies and vehicle designs upon which the study team performed processing analyses. An on-orbit SSF refurbishment crew of four dedicated to OEXP vehicle processing was baselined for all studies. In some Instances, LaRC modified the vehicle designs, launch manifests, or mission scenarios provided by MSFC to obtain specific data from the processing analyses. The results from the following case studies analyzed during 1989 are provided in this report: Phobos Gateway On-Orbit Assembly and Launch, Lunar Evolution Vehicle On-Orbit Refurbishment, and Mars Mission Vehicle On-Orbit Assembly and Launch. In addition, a concept for facility accommodations at Space Station Freedom (SSF) was developed and support equipment to be provided at the facility was defined. In support of the MSFC Launch/On-Orbit Processing (LOOP) study, LaRC asked us to assess ground and on-orbit processing Impacts resulting from launching the OEXP vehicles on several different ETO launch vehicles. Results developed by this study, Including processing tasks and times, and personnel and equipment requirements, will be entered Into the VPOD data base. VPOD will be used by LaRC to analyze future OEXP vehicles configurations, SSF facility and resource Impacts, and life cycle cost predictions.
The requirements, conceptual design, tradeoffs, procedures, and techniques for orbital assembly of the support structure of the microwave power transmission system and the radio astronomy telescope are described. Thermal and stress analyses, packaging, alignment, and subsystems requirements are included along with manned vs. automated and transportation tradeoffs. Technical and operational concepts for the manned and automated maintenance of satellites were investigated and further developed results are presented.
Venting and leakage torque effects on attitude control of Skylab orbital assembly by control moment gyros
During the International Space Station’s (ISS’s) on-orbit assembly and outfitting, a series of engineering analyses was conducted to evaluate how effective the passive trace contaminant control (TCC) methods were relative to providing adequate operational margin for the active TCC equipment’s capabilities aboard the ISS. These analyses were based on habitable module and cargo vehicle offgassing test results. The offgassing test for the fully assembled module or cargo vehicle is an important preflight spacecraft evaluation method that has been used successfully during all crewed spacecraft programs to provide insight into how effectively the passive contamination control methods limit the equipment offgassing component of the overall trace contaminant generation load. The progression of TCC assessments beginning in 1998 with the ISS’s first habitable element launch and continuing through the final pressurized element’s arrival in 2010 are presented. Early cargo vehicle flight assessments between 2008 and 2011 are also presented as well as a discussion on predictive methods for assessing cargo via a purely analytical technique.
A preliminary design for a weldable truss joint for on-orbit assembly of large space structures is described. The joint was designed for ease of assembly, for structural efficiency, and to allow passage of fluid (for active cooling or other purposes) along the member through the joint. The truss members were assumed to consist of graphite/epoxy tubes to which were bonded 2219-T87 aluminum alloy end fittings for welding on-orbit to truss nodes of the same alloy. A modified form of gas tungsten arc welding was assumed to be the welding process. The joint was designed to withstand the thermal and structural loading associated with a 120-ft diameter tetrahedral truss intended as an aerobrake for a mission to Mars.
Proposed Mars Sample Return (MSR) missions would require on-orbit assembly of containment vessels to meet backward Planetary Protection requirements and transfer of the sample container through various stations and positions. Some operations would have to be performed autonomously, and others would require ground-in-loop decision-making stages and verification processes. One concept design for an Earth Return Orbiter (ERO) Capture, Contain, and Return System (CCRS) Transfer Mechanism (TM) is a multi-Degree of Freedom (DOF) manipulator that utilizes a passive End Effector (EE) to assist in containment vessel assembly. To converge on a feasible design, a robotic system process has been instantiated. This process is composed of three main phases: robotic problem definition (operating environment, operations/functions, system goals), robotic solution selection (trade studies on the number of degrees of freedom, number of mechanisms, types of mechanisms), robotic solution design, implementation, and verification and validation (kinematic configuration, robotic and kinematic analysis and topology optimization of components). As a final product of this process, a half-scale functional prototype of the TM was developed to demonstrate the end-to-end operation capability.
The contents of this section contain the initial concepts developed for the In-orbit assembly of a Manned Mars Vehicle and for the Earth-to-Orbit (ETO) delivery of the required hardware and propellant. Two (2) Mars vehicle concepts (all-propulsive and all-aerobrake) and two (2) ET0 Vehicle concepts were investigated. Both Mars Vehicle concepts are described in Reference 1, and both ETO Vehicle concepts are described in Reference 2. The all-aerobrake configuration reduces the number of launches and time required to deliver the necessary hardware/propellent to orbit. Use of the larger of the 2 ETO Vehicles (HLLV) further reduces the number of launches and delivery time; however, this option requires a completely new vehicle and supporting facilities.
Developmental efforts conducted under NASA-Marshall aegis toward on-orbit assembly for manned Mars mission transfer vehicles (MTV) are presented. The MTV types considered encompass those with cryogenic/aerobraking propulsion, all-cryogenic propulsion, nuclear-thermal propulsion (NTP), nuclear-electric propulsion (NEP), and solar-electric propulsion (SEP). Attention is given to NTP, NEP, and SEP MTVs, in light of the requirements posed by the assembly environment and assembly platform designs. Much important design-related information is being derived from the Long Duration Exposure Facility.
As spaceflight moves toward commercial solutions for Crew Vehicles and Space Stations, opportunity exists to lower costs with novel designs. Probe and cone docking systems provide a lightweight, low cost, and high-performance docking solution. This work revisits the Apollo probe and cone design and modifies it for the requirements of today’s computer-controlled spacecraft. This new system is called the Advanced Apollo Orbital Assembly (APOA) system, and is intended to support satellite, cargo, and space station assembly missions. A simulation of the APOA was programmed, components were sized, and a design was created by scaling the probe to the size of an EELV Secondary Payload Adapter (ESPA) tunnel. Prototype test hardware was 3D printed using Fused Deposition Modeling (FDM) methods with Polylactic Acid (PLA) material. Testing of the APOA-ESPA was conducted at Marshall Space Flight Center’s (MSFC) Flat Floor, and a test-correlated simulation is used to evaluate a Monte-Carlo of Initial Contact Conditions (ICC’s) to establish baseline performance. The successful development, test, and correlation of the APOA-ESPA proves the design validity and increases Technology Readiness Level (TRL) from 2 to 4. This work opens the door to construction of an APOA-ESPA from flight like materials, and to develop a larger scale prototype APOA. When the full scale APOA is incorporated with the Common Berthing Mechanism (CBM), becomes the Hybrid Berthing System (HBS), which allows for berthing without a robotic arm.
The topics are presented in viewgraph form and include the following: definition and scope of space construction; orbital assembly and construction; lunar base construction; and Mars base construction.
A procedure that enables astronauts in extravehicular activity (EVA) to perform efficient on-orbit assembly of large paraboloidal precision reflectors is presented. The procedure and associated hardware are verified in simulated Og (neutral buoyancy) assembly tests of a 14 m diameter precision reflector mockup. The test article represents a precision reflector having a reflective surface which is segmented into 37 individual panels. The panels are supported on a doubly curved tetrahedral truss consisting of 315 struts. The entire truss and seven reflector panels were assembled in three hours and seven minutes by two pressure-suited test subjects. The average time to attach a panel was two minutes and three seconds. These efficient assembly times were achieved because all hardware and assembly procedures were designed to be compatible with EVA assembly capabilities.
A concept is described for the assembly of the outboard PV modules for Space Station Freedom. Analysis of the on-orbit assembly operations was performed using CADAM design graphics software. A scenario for assembly using the various assembly equipment, as currently defined, is described in words, tables and illustrations. This work is part of ongoing studies in the area of space station assembly. The outboard PV module and the assembly equipment programs are all in definition and preliminary design phases. An input is provided to the design process of assembly equipment programs. It is established that the outboard PV module assembly operations can be performed using the assembly equipment currently planned in the Space Station Freedom Program.