Bittinger, Samantha A.

NASA NTRS2019

European Service Module - Structural Test Article (E-STA) Building Block Test Approach and Model Correlation Observations

The Orion European Service Module - Structural Test Article (E-STA) underwent sine vibration testing in 2016 using the Mechanical Vibration Facility (MVF) multi-axis shaker system at NASA Glenn Research Center’s (GRC) Plum Brook Station (PBS) Space Power Facility (SPF). The main objective was to verify the structural integrity of the European Service Module (ESM) under sine sweep dynamic qualification vibration testing. A secondary objective was to perform a fixed-base modal survey, while E-STA was still mounted to MVF, in order to achieve a test correlate the finite element model (FEM). To facilitate the E-STA system level correlation effort, a building block test approach was implemented. Modal tests were performed on two major subassemblies, the crew module/launch abort structure (CM/LAS) and the crew module adapter (CMA) mass simulators. These subassembly FEMs were individually correlated and then integrated into the E-STA FEM prior to the start of the E-STA sine vibration test. This paper summarizes the modal testing and model correlation efforts of both of these subassemblies and how the building block approach assisted in the overall correlation of the E-STA FEM. This paper will also cover modeling practices that should be avoided, recommended instrumentation positioning on complex structures, and the importance of the FEM geometrically matching CAD in sufficient detail in order to adequately replicate internal load paths. The goal of this paper is to inform the reader of the hard earned lessons learned and pitfalls to avoid when applying a building block test approach.

Winkel, James P.↗

NASA NTRS2017

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing

The NASA Orion Multi-Purpose Crew Vehicle (MPCV), comprised of the Service Module, the Crew Module, and the Launch Abort System, is the next generation human spacecraft designed and built for deep space exploration. Orion will launch on NASAs new heavy-lift rocket, the Space Launch System. The European Space Agency (ESA) is responsible for providing the propulsion sub-assembly of the Service Module to NASA, called the European Service Module (ESM). The ESM is being designed and built by Airbus Safran Launchers for ESA. Traditionally, NASA has utilized reverberant acoustic testing for qualification of spaceflight hardware. The ESM Structural Test Article (E-STA) was tested at the NASA Plum Brook Stations (PBS) Reverberant Acoustic Test Facility in April-May 2016. However, Orion is evaluating an alternative acoustic test method, using direct field acoustic excitation, for the MPCVs Service Module and Crew Module. Lockheed Martin is responsible for the Orion proof-of-concept direct field acoustic test program. The E-STA was exposed to direct field acoustic testing at NASA PBS in February 2017. This paper compares the dynamic response of the E-STA structure and its components to both the reverberant and direct field acoustic test excitations. Advantages and disadvantages of direct field acoustic test excitation method are discussed.

Acoustics↗

NASA NTRS2017

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing

The NASA Orion Multi-Purpose Crew Vehicle (MPCV), comprised of the Service Module, the Crew Module, and the Launch Abort System, is the next generation human spacecraft designed and built for deep space exploration. Orion will launch on NASAs new heavy-lift rocket, the Space Launch System. The European Space Agency (ESA) is responsible for providing the propulsion sub-assembly of the Service Module to NASA, called the European Service Module (ESM). The ESM is being designed and built by Airbus Safran Launchers for ESA. Traditionally, NASA has utilized reverberant acoustic testing for qualification of spaceflight hardware. The ESM Structural Test Article (E-STA) was tested at the NASA Plum Brook Stations (PBS) Reverberant Acoustic Test Facility in April-May 2016. However, Orion is evaluating an alternative acoustic test method, using direct field acoustic excitation, for the MPCVs Service Module and Crew Module. Lockheed Martin is responsible for the Orion proof-of-concept direct field acoustic test program. The E-STA was exposed to direct field acoustic testing at NASA PBS in February 2017. This paper compares the dynamic response of the E-STA structure and its components to both the reverberant and direct field acoustic test excitations. Advantages and disadvantages of direct field acoustic test excitation method are discussed.

Acoustics↗

NASA NTRS2016

Acoustic Analysis and Design of the E-STA MSA Simulator

The Orion European Service Module Structural Test Article (E-STA) Acoustic Test was completed in May 2016 to verify that the European Service Module (ESM) can withstand qualification acoustic environments. The test article required an aft closeout to simulate the Multi-Purpose Crew Vehicle (MPCV) Stage Adapter (MSA) cavity, however, the flight MSA design was too cost-prohibitive to build. NASA Glenn Research Center (GRC) had 6 months to design an MSA Simulator that could recreate the qualification prediction MSA cavity sound pressure level to within a reasonable tolerance. This paper summarizes the design and analysis process to arrive at a design for the MSA Simulator, and then compares its performance to the final prediction models created prior to test.

acoustics↗

NASA NTRS2012

Tone Noise Predictions for a Spacecraft Cabin Ventilation Fan Ingesting Distorted Inflow and the Challenges of Validation

A fan tone noise prediction code has been developed at NASA Glenn Research Center that is capable of estimating duct mode sound power levels for a fan ingesting distorted inflow. This code was used to predict the circumferential and radial mode sound power levels in the inlet and exhaust duct of an axial spacecraft cabin ventilation fan. Noise predictions at fan design rotational speed were generated. Three fan inflow conditions were studied: an undistorted inflow, a circumferentially symmetric inflow distortion pattern (cylindrical rods inserted radially into the flowpath at 15deg, 135deg, and 255deg), and a circumferentially asymmetric inflow distortion pattern (rods located at 15deg, 52deg and 173deg). Noise predictions indicate that tones are produced for the distorted inflow cases that are not present when the fan operates with an undistorted inflow. Experimental data are needed to validate these acoustic predictions, as well as the aerodynamic performance predictions. Given the aerodynamic design of the spacecraft cabin ventilation fan, a mechanical and electrical conceptual design study was conducted. Design features of a fan suitable for obtaining detailed acoustic and aerodynamic measurements needed to validate predictions are discussed.

Koch, L. Danielle↗

NASA NTRS2011

Tone Noise Predictions for a Spacecraft Cabin Ventilation Fan Ingesting Distorted Inflow and the Challenges of Validation

A fan tone noise prediction code has been developed at NASA Glenn Research Center that is capable of estimating duct mode sound power levels for a fan ingesting distorted inflow. This code was used to predict the circumferential and radial mode sound power levels in the inlet and exhaust duct of an axial spacecraft cabin ventilation fan. Noise predictions at fan design rotational speed were generated. Three fan inflow conditions were studied: an undistorted inflow, a circumferentially symmetric inflow distortion pattern (cylindrical rods inserted radially into the flowpath at 15deg, 135deg, and 255deg), and a circumferentially asymmetric inflow distortion pattern (rods located at 15deg, 52deg and 173deg). Noise predictions indicate that tones are produced for the distorted inflow cases that are not present when the fan operates with an undistorted inflow. Experimental data are needed to validate these acoustic predictions, as well as the aerodynamic performance predictions. Given the aerodynamic design of the spacecraft cabin ventilation fan, a mechanical and electrical conceptual design study was conducted. Design features of a fan suitable for obtaining detailed acoustic and aerodynamic measurements needed to validate predictions are discussed.

Koch, L. Danielle↗