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This slide presentation reviews the payload processing functions at Kennedy Space Center. It details some of the payloads processed at KSC, the typical processing tasks, the facilities available for processing payloads, and the capabilities and customer services that are available.
An investigation is described which examined the extent to which the experiment hardware and operational requirements can be met by automatic control and material handling devices; payload and system concepts are defined which make extensive use of automation technology. Topics covered include experiment requirements and hardware data, capabilities and characteristics of industrial automation equipment and controls, payload grouping, automated payload conceptual design, space processing payload preliminary design, automated space processing payloads for early shuttle missions, and cost and scheduling.
The shuttle payload processing facilities at the Kennedy Space Center and the payload processing and integrating procedures are briefly outlined.
General and specific quantitative and qualitative results were identified from a study of actual operational experience while processing 186 science, applications, and commercial payloads for the first 5 years of Space Transportation System (STS) operations at the National Aeronautics and Space Administration's (NASA) John F. Kennedy Space Center (KSC). All non-Department of Defense payloads from STS-2 through STS-33 were part of the study. Historical data and cumulative program experiences from key personnel were used extensively. Emphasis was placed on various program planning and events that affected KSC processing, payload experiences and improvements, payload hardware condition after arrival, services to customers, and the impact of STS operations and delays. From these initial considerations, operational drivers were identified, data for selected processing parameters collected and analyzed, processing criteria and options determined, and STS payload results and conclusions reached. The study showed a significant reduction in time and effort needed by STS customers and KSC to process a wide variety of payload configurations. Also of significance is the fact that even the simplest payloads required more processing resources than were initially assumed. The success to date of payload integration, testing, and mission operations, however, indicates the soundness of the approach taken and the methods used.
This paper identifies general and specific quantitative and qualitative results from a study of actual operational experiences while processing 185 science, applications, and commercial payloads for the first five years of STS operations at NASA's Kennedy Space Center (KSC). All the non-DOD payloads from STS-2 through STS-33 were part of the study. The emphasis was placed on various program planning and events that affected KSC processing, payload experiences and improvements, payload hardware condition after arrival, services to customers, and the impact of STS operations and delays. From these initial considerations, operational drivers were identified, data for selected processing measurements collected and analyzed, processing criteria and options determined, and STS payload results and conclusions reached. The study showed a significant reduction in time and effort needed by STS customers and KSC to process a wide variety of payload configurations, although even the simplest payloads required more processing resources and time than were initially assumed.
KSC International Space Station (ISS) payload processing and facilities have changed significantly from what was utilized for many years to prepare Spacelab experiment payloads for the Shuttle. Presented will be an overview of the processes and facilities to be used for preparing payloads to be launched on the Shuttle to the ISS.
Two basic systems of Shuttle payload and checkout are discussed. The first system is called 'off-line' checkout and checks out payloads or payload segments after they are brought to the launch complex laboratories, as individual units and transfer them to an integration facility where they are assembled into a total Shuttle payload. In this scheme all payload assembly and checkout is performed away from the Orbiter. Any problems concerning the payloads will allow rescheduling another payload for flight and therefore not subjecting the Orbiter to delays in its recycling flow. The second payload processing scheme is the 'on-line' checkout which employs a 'factory to pad' concept. Payloads are delivered directly to the pad, placed in the Payload Changeout Room where they are checked out and integrated and, after completion of servicing, are installed vertically into the Orbiter. A combination of off-line and on-line processing will be used to meet all flight requirements.
The philosophy and the operations concept of the VentureStar(tm) payload processing system is presented. The goal of VentureStar(tm) operations is to provide low cost access to space. This is to be achieved through the design of the vehicle, and operability of the ground system. Specifically, this is to be accomplished through rapid turnaround cycles, increased launch rate, high system reliability and availability and reduced required operations personnel. This is presented in viewgraph format.
In the wake of the Challenger accident, NASA has placed an increasing emphasis on trend analysis techniques. These analyses provide meaningful insights into system and hardware status, and also develop additional lessons learned from historical data to aid in the design and operation of future space systems. This paper presents selected results from such a trend analysis study that was conducted on the problem report data files for the Shuttle Payload Processing activities. Specifically, the results shown are for the payload canister system which interfaces with and transfers payloads from their processing facilities to the orbiter.
An overview is presented of the processing cycles of horizontally integrated and vertically integrated Shuttle payloads at the Kennedy Space Center. Attention is given to the integration of these payloads into Shuttle-ready cargos and the installation of the cargo into the Orbiter. Diagrams are presented of: (1) Shuttle processing flow at KSC, (2) payload processing flow, (3) typical items of multimission support equipment, (4) primary items of checkout equipment, (5) payload ready for transfer into the canister for vertical processing, and (6) the rotating service structure retracted to receive the payload canister.
A NASA-KSC study on payload ground processing activities in support of Expendable Launch Vehicle (ELV) launches at Cape Canaveral Air Force Station from January 1977 through February 1988, showed that nearly half of the payloads experienced schedule delays. While about 10 percent of the delays were weather-related, over 65 percent were caused by payload/launch vehicle problems. The planned processing time was exceeded by more than two weeks in most cases. Nearly 30 percent of the payloads required some storage time.
Experimental payloads flown to the International Space Station provide us with valuable research conducted in a microgravity environment not attainable on earth. The Mice Drawer System is an experiment designed by Thales Alenia Space Italia to study the effects of microgravity on mice. It is designed to fly to orbit on the Space Shuttle Utilization Logistics Flight 2 in October 2008, remain onboard the International Space Station for approximately 100 days and then return to earth on a following Shuttle flight. The experiment apparatus will be housed inside a Double Payload Carrier. An engineering model of the Double Payload Carrier was sent to Kennedy Space Center for a fit check inside both Shuttles, and the rack that it will be installed in aboard the International Space Station. The Double Payload Carrier showed a good fit quality inside each vehicle, and Thales Alenia Space Italia will now construct the actual flight model and continue to prepare the Mice Drawer System experiment for launch.
An overview is given of the definition of research requirements and derivation of engineering design requirements for a group of 77 representative applications of space processing. Representative requirements are documented for applied research in space on biological processes, chemical/fluid phenomena, solidification processes, and glass/ceramics processes. Design requirements for payload equipment to accommodate these research requirements are presented in engineering terms, such as power requirements, schematic diagrams, etc. In addition, a summary of the 77 applied research topics is included.
The workshop for Lunar Science Applications brings like minded people together to discuss ways to get back to the Moon and showcase cutting edge science and engineering that will help make that a reality. This presentation will be provided to the attendees as a way to showcase and highlight how KSC's over 50 years experience with payload testing, integration, and processing can help the commercial and government space in getting back to the Moon.
The helpful hints herein describe, from a system perspective, the functional flow of hardware and software. The flow will begin at the experiment development stage and continue through build-up, test, verification, delivery, launch and deintegration of the experiment. An effort will be made to identify those interfaces and transfer functions of processing that can be improved upon in the new world of 'Faster, Better, and Cheaper.' The documentation necessary to ensure configuration and processing requirements satisfaction will also be discussed. Hints and suggestions for improvements to enhance each phase of the flow will be derived from extensive experience and documented lessons learned. Charts will be utilized to define the functional flow and a list of 'lessons learned' will be addressed to show applicability. In conclusion, specific improvements for several areas of hardware processing, procedure development and quality assurance, that are generic to all Small Payloads, will be identified.
The extent was investigated to which experiment hardware and operational requirements can be met by automatic control and material handling devices; payload and system concepts that make extensive use of automation technology are defined. Hardware requirements for each experiment were established and tabulated, and investigations of applicable existing hardware were documented. The capabilities and characteristics of industrial automation equipment, controls, and techniques are presented in the form of a summary of applicable equipment characteristics in three basic mutually-supporting formats. Facilities for performing groups of experiments are defined along with four levitation groups and three furnace groups; major hardware elements required to implement them were identified. A conceptual design definition of ten different automated processing facilities is presented along with the specific equipment to implement each facility and the design layouts of the different units. Constraints and packaging, weight, and power requirements for six payloads postulated for shuttle missions in the 1979 to 1982 time period were examined.
Discussed are the definitions of facilities which will serve the research needs of a large group of users. These facilities (payloads) are derived by several combinations of items from a large inventory of modular, reusable, research equipment which enables ready response to many flight opportunities. Workable concepts have been prepared and submitted to the Spacelab design activity. These designs permit the flying of either partial or dedicated payloads. The technical integrity of the modular approach to payload design/integration and the utility of commercial-equipment technology are also addressed in this paper.
This paper discusses the definition of facilities which will serve the research needs of a large group of users. These facilities (payloads) are derived by several combinations of items from a large inventory of modular, reusable research equipment, enabling us to respond to many flight opportunities. Workable concepts have been laid out and inputted into the Spacelab design activity. These designs permit the flying of either partial or dedicated payloads. Also addressed in this paper are the technical integrity of the modular approach to payload design and integration, and the utility of commercial equipment technology.