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NASA NTRS2011

Design Considerations for a Launch Vehicle Development Flight Instrumentation System

When embarking into the design of a new launch vehicle, engineering models of expected vehicle performance are always generated. While many models are well established and understood, some models contain design features that are only marginally known. Unfortunately, these analytical models produce uncertainties in design margins. The best way to answer these analytical issues is with vehicle level testing. The National Aeronautics and Space Administration respond to these uncertainties by using a vehicle level system called the Development Flight Instrumentation, or DFI. This DFI system can be simple to implement, with only a few measurements, or it may be a sophisticated system with hundreds of measurement and video, without a recording capability. From experience with DFI systems, DFI never goes away. The system is renamed and allowed to continue, in most cases. Proper system design can aid the transition to future data requirements. This paper will discuss design features that need to be considered when developing a DFI system for a launch vehicle. It will briefly review the data acquisition units, sensors, multiplexers and recorders, telemetry components and harnessing. It will present a reasonable set of requirements which should be implemented in the beginning of the program in order to start the design. It will discuss a simplistic DFI architecture that could be the basis for the next NASA launch vehicle. This will be followed by a discussion of the "experiences gained" from a past DFI system implementation, such as the very successful Ares I-X test flight. Application of these design considerations may not work for every situation, but they may direct a path toward success or at least make one pause and ask the right questions.

Johnson, Martin L.↗

NASA NTRS2006

Developmental Flight Instrumentation System for the Crew Launch Vehicle

The National Aeronautics and Space Administration is developing a new launch vehicle to replace the Space Shuttle. The Crew Launch Vehicle (CLV) will be a combination of new design hardware and heritage Apollo and Space Shuttle hardware. The current CLV configuration is a 5 segment solid rocket booster first stage and a new upper stage design with a modified Apollo era J-2 engine. The current schedule has two test flights with a first stage and a structurally identical, but without engine, upper stage. Then there will be two more test flights with a full complement of flight hardware. After the completion of the test flights, the first manned flight to the International Space Station is scheduled for late 2012. To verify the CLV's design margins a developmental flight instrumentation (DFI) system is needed. The DFI system will collect environmental and health data from the various CLV subsystem's and either transmit it to the ground or store it onboard for later evaluation on the ground. The CLV consists of 4 major elements: the first stage, the upper stage, the upper stage engine and the integration of the first stage, upper stage and upper stage engine. It is anticipated that each of CLVs elements will have some version of DFI. This paper will discuss a conceptual DFI design for each element and also of an integrated CLV DFI system.

Crawford, Kevin↗

NASA NTRS2001

Flight Computer Processing Avionics for Space Station Microgravity Experiments: A Risk Assessment of Commercial Off-the-Shelf Utilization

NASA/Marshall Space Flight Center (MSFC) is continually looking for ways to reduce the costs and schedule and minimize the technical risks during the development of microgravity programs. One of the more prominent ways to minimize the cost and schedule is to use off-the-shelf hardware (OTS). However, the use of OTS often increases the risk. This paper addresses relevant factors considered during the selection and utilization of commercial off-the-shelf (COTS) flight computer processing equipment for the control of space station microgravity experiments. The paper will also discuss how to minimize the technical risks when using COTS processing hardware. Two microgravity experiments for which the COTS processing equipment is being evaluated for are the Equiaxed Dendritic Solidification Experiment (EDSE) and the Self-diffusion in Liquid Elements (SDLE) experiment. Since MSFC is the lead center for Microgravity research, EDSE and SDLE processor selection will be closely watched by other experiments that are being designed to meet payload carrier requirements. This includes the payload carriers planned for the International Space Station (ISS). The purpose of EDSE is to continue to investigate microstructural evolution of, and thermal interactions between multiple dendrites growing under diffusion controlled conditions. The purpose of SDLE is to determine accurate self-diffusivity data as a function of temperature for liquid elements selected as representative of class-like structures. In 1999 MSFC initiated a Center Director's Discretionary Fund (CDDF) effort to investigate and determine the optimal commercial data bus architecture that could lead to faster, better, and lower cost data acquisition systems for the control of microgravity experiments. As part of this effort various commercial data acquisition systems were acquired and evaluated. This included equipment with various form factors, (3U, 6U, others) and equipment that utilized various bus structures, (VME, PC104, STD bus). This evaluation of hardware was performed in conjunction with a trade study that considered over twenty (20) different factors relevant to the selection of an optimum design approach. These factors included; safety, sizing and timing, radiation hardness and single event upset, power consumption, heat dissipation, size and volume, expected service life, maintainability, heritage, operating systems, requirements for software reuse, availability of compatible interface boards, relative cost, schedule, reliability, EMI/EMC factors, "hot swap" capability, standards for conduction cooling, I/O capabilities, unique carrier requirements and operating system considerations. The approach to evaluate Safety as part of this study included a review of the Preliminary Hazard Analysis (PHA) for each of the experiment designs and a determination of how each hazard could be addressed and eliminated when different processors were selected. This included evaluating various design approaches and trade-offs between fault tolerant designs and fail-safe designs in accordance with NSTS 1700.7B. This will include the results of radiation testing where available. Various operating systems, such as VxWorks, Linux, QNX, and Embedded NT are evaluated and the advantages and disadvantages of their utilization are also addressed. Design implementation strategies for the various operating systems are considered and discussed. This paper presents the results and recommendations from this trade study. Preliminary conclusions from this study are that safety concerns from lack or radiation testing on COTS equipment can be addressed by additional testing and design considerations, the PC104 bus provided adequate I/O for the SDLE and EDSE microgravity experiments, and PC104 bus components offered significant advantages over VME and cPCI for weight and space reductions.

Estes, Howard↗

NASA NTRS2001

Determination of an Optimal Commercial Data Bus Architecture for a Flight Data System

NASA/Marshall Space Flight Center (MSFC) is continually looking for methods to reduce cost and schedule while keeping the quality of work high. MSFC is NASA's lead center for space transportation and microgravity research. When supporting NASA's programs several decisions concerning the avionics system must be made. Usually many trade studies must be conducted to determine the best ways to meet the customer's requirements. When deciding the flight data system, one of the first trade studies normally conducted is the determination of the data bus architecture. The schedule, cost, reliability, and environments are some of the factors that are reviewed in the determination of the data bus architecture. Based on the studies, the data bus architecture could result in a proprietary data bus or a commercial data bus. The cost factor usually removes the proprietary data bus from consideration. The commercial data bus's range from Versa Module Eurocard (VME) to Compact PCI to STD 32 to PC 104. If cost, schedule and size are prime factors, VME is usually not considered. If the prime factors are cost, schedule, and size then Compact PCI, STD 32 and PC104 are the choices for the data bus architecture. MSFC's center director has funded a study from his discretionary fund to determine an optimal low cost commercial data bus architecture. The goal of the study is to functionally and environmentally test Compact PCI, STD 32 and PC 104 data bus architectures. This paper will summarize the results of the data bus architecture study.

Crawford, Kevin↗

NASA NTRS2000

Development of a Vehicle Health Monitoring System for the Space Shuttle Solid Rocket Booster Program

During their brief flight, the space shuttle solid rocket boosters (SRBs) experience a severe environment. This environment in most cases is unknown. When the design engineers believe they understand the environments, something new occurs. For example, at water impact several SRBs have sustained noticeable structural damage. The severity of the damage is usually dependent upon the waves that the SRB encounter at splashdown. The space shuttle is presently scheduled to fly until 2030. To support the shuttle flight schedule, the avionics on the SRB's will need to be upgraded. The environments on the different sections of the SRB will need to be defined more completely to properly qualify the avionics for multiple flights. The combination of new avionics systems and unknown flight environments led Marshall Space Flight Center's (MSFC) SRB Project Office to request the Science and Engineering (S&E) Directorate to develop a stand-alone data acquisition system that could collect data from any area of the booster. The Enhanced Data Acquisition System (EDAS) was developed to meet this request. However, the EDAS has some technical drawbacks that needed resolved. To answer the EDAS problems, the SRB Project Office has funded MSFC's Avionics Department to begin investigating a new vehicle health monitoring (VHM) system. The major requirements are the system shall have 64 channels, have programmable sample rates up to 10,000 samples per second, have sufficient memory for a twenty minute flight and not interfere with existing operational flight avionics hardware. This paper will describe the effort to develop a VHM system that can meet the SRB requirements.

Crawford, Kevin↗

NASA NTRS1999

Update of the Development of a Low Cost Data Acquisition System for the Space Shuttle Solid Rocket Booster Program

The space shuttle solid rocket boosters (SRBs) experience a severe environment during their brief flight. During the last few years several SRB's have sustained noticeable structural damage. The environmental characteristics (vibration, structure, and thermal) encountered by the SRB's during ascent, descent and water impact are in most cases unknown. A developmental flight instrumentation (DFI) system collected data from the SRBs' first four flights in the early 1980's, and after the first three flights during the shuttle return-to-flight phase after the Challenger accident. However, the DFI data collected are of low fidelity and do not correlate well with cases of observed structural damage. The DFI system was evaluated for reuse, but the cost to fly it was prohibitive. The space shuttle is presently scheduled to fly until 2030. To support the shuttle flight schedule, avionics on the SRB's will be upgraded. The environments on the different sections of the SRB will need to be defined more completely to properly qualify the avionics for multiple flights. The DFI data previously gathered do not provide enough information to properly qualify the avionics. Marshall Space Flight Center's (MSFC) SRB Project Office requested the Science and Engineering (S&E) Directorate to develop a stand-alone data acquisition system that could collect data from any area of the booster. In answer to this requirement, S&E developed the Enhanced Data Acquisition System (EDAS). To minimize development time and cost, the development team used state-of-the-art commercial off the shelf (COTS) equipment. The first two flights of this system occurred on shuttle mission STS-91 in June 1998 and STS-95 in October 1998. Twenty-one measurements were successfully recorded on the STS-91 right hand booster, providing new accelerometer, strain, temperature, and heating rate data to analysts. Twenty-four measurements were successfully recorded on the STS-95 left hand booster, providing data from the booster and the external tank. This paper summarizes the effort to develop, test, qualify and fly the EDAS to meet SRB flight and data collection requirements.

Crawford, Kevin↗

NASA NTRS1999

Using a Commerical off the Shelf Data Acquisition System for the Space Shuttle Solid Rocket Booster Program

The space shuttle solid rocket boosters (SRBs) experience a severe environment during their brief flight. During the last few years several SRB's have sustained noticeable structural damage. The environmental characteristics (vibration, structure, and thermal) encountered by the SRB's during ascent, descent and water impact are in most cases unknown. A developmental flight instrumentation (DFI) system collected data from the SRBs' first four flights in the early 1980's, and after the first three flights during the shuttle return-to-flight phase after the Challenger accident. However, the DFI data collected are of low fidelity and do not correlate well with cases of observed structural damage. The DFI system was evaluated for reuse, but the cost to fly it was prohibitive. The space shuttle is presently scheduled to fly until 2030. To support the shuttle flight schedule, avionics on the SRB's will be upgraded. The environments on the different sections of the SRB will need to be defined more completely to properly qualify the avionics for multiple flights. The DFI data previously gathered do not provide enough information to properly qualify the avionics. Marshall Space Flight Center's (MSFC) SRB Project Office requested the Science and Engineering (S&E) Directorate to develop a stand-alone data acquisition system that could collect data from any area of the booster. In answer to this requirement, S&E developed the Enhanced Data Acquisition System (EDAS). To minimize development time and cost, the development team used state-of-the-art commercial off the shelf (COTS) equipment. The first two flights of this system occurred on shuttle mission STS-91 in June 1998 and STS-95 in October 1998. Twenty-one measurements were successfully recorded on the STS-91 right hand booster, providing new accelerometer, strain, temperature, and heating rate data to analysts. Twenty-four measurements were successfully recorded on the STS-95 left hand booster, providing data from the booster and the external tank. This paper summarizes the effort to develop, test, qualify and fly the EDAS to meet SRB flight and data collection requirements.

Crawford, Kevin↗

NASA NTRS1998

Development of a Low Cost Data Acquisition System for the Solid Rocket Booster Program

The Space Transportation System's (STS) Solid Rocket Boosters (SRBs) experience a severe environment during their brief flight. During the last few years several SRB's have sustained noticeable structural damage. The environmental characteristics (vibration, structure, and thermal) encountered by the SRB's during ascent, descent and water impact are in most cases unknown. A developmental flight instrumentation (DFI) system collected data from the SRB's first four flights in the early 1980's, and after the first three flights during the shuttle return-to-flight phase after the Challenger accident. However, the DFI data collected are of low fidelity and do not correlate well with the observed structural damage. The DFI system was evaluated for reuse, but the cost to fly it was prohibitive. The STS is presently scheduled to fly until 2030. To support the STS schedule the avionics on SRB's will be upgraded. The environments on the different sections of the SRB will need to be defined to properly qualify the avionics for multiple flights. The DFI data previously gathered does not provide enough information to properly qualify the avionics. Marshall Space Flight Centers (MSFC) SRB Project Office requested the Science and Engineering Directorate to develop a self contained data acquisition system that could collect data from any area of the booster. This paper summarizes the effort to develop, test, qualify and fly an Enhanced Data Acquisition System (EDAS) using state-of-the-art commercial off the shelf (COTS) equipment. The first flight of this system occurred on shuttle mission STS-91 in June 1998.

Crawford, Kevin↗

NASA NTRS1998

Design of a Low Cost Avionics System for Launch Vehicles

Marshall Space Flight Center has long been one of the leaders in development of propulsion systems. Due to current launch vehicle costs, Marshall Space Flight Centers (MSFC) Advanced Space Transportation Program (ASTP) office has emphasized the development of low cost launch vehicles. The Bantam launch vehicle is one of the primary programs that has low cost as a requirement. One of the driving factors for a low cost launch vehicle is a low cost avionics system. This paper will summarize MSFC's Astrionics Laboratories efforts in designing a low cost avionics system. MSFC has done Phase A avionics system design and has been working with various contractors on a Phase B preliminary avionics design. Deriving the major requirements, trade studies and cost drivers are some of the topics to be discussed.

Crawford, Kevin↗

NASA NTRS1997

Development of the Flight Test Telemetry System for Clipper Graham: A New Way to do Business

Since the beginning of NASA, there has been one way to do business. To procedure flight hardware you did things a certain way, to monitor contracts you did things a certain way and to support tests you did things a certain way. When the Delta Clipper Experimental (DC-X) space flight test vehicle was being upgraded (to the DC-XA, later called the Clipper Graham), the opportunity to change the way NASA did business presented itself The development of a flight test telemetry system (FTTS) for the Clipper Graham presented the perfect opportunity to change the way NASA did business. This paper will discuss the differences from the old way to the new way of doing business during the development of the FTTS from the conceptual stage thru the flight stages. The major focus will be the pulse code modulation system of the FTTS. Topics that will be discussed are working with procurement, working with contractors and subcontractors, supporting ground and flight testing and lessons learned.

Blue, Lisa↗