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Mission Summary of Cassini Spacecraft Guidance and Control Hardware Health and Performance

The Cassini-Huygens mission ended on September 15, 2017, after nearly two decades in ight. The well-designed Cassini spacecraft had robust hardware that permitted two extended missions, lasting nine years longer than the expected prime mission. At the end of the mission, the Attitude and Articulation Control Subsystem (AACS) was using two pieces of redundant back-up of hardware, one reaction wheel and the hydrazine thruster branch, due to hardware anomalies earlier in the mission. The back-up hardware performed nominally through the rest of mission. The prime reaction wheels at the end of the mission had reached more than 130% of the consumable limit for number of revolutions. No thruster on either thruster branch accumulated more than 45% of the consumable limits. The inertial reference unit slightly exceeded the pre-launch requirements on bias error, but as the software continuously estimated this value in ight, the attitude estimation was not adversely a ected. The star trackers performed nominally, and though there was a spacecraft anomaly in 1998 related to the star trackers, the origin was not in hardware itself. The Sun sensors and accelerometer both performed as expected and met all requirements throughout the mission. Ultimately, the lifetime of the Cassini spacecraft was not limited by hardware performance. Planetary protection requirements necessitated the end of the mission as the spacecraft's propellant reserves depleted, and Cassini plunged into Saturn's atmosphere with a healthy attitude control system.

Stupik, Joan↗

Internal erosion rates of a 10-kW xenon ion thruster

A 30 cm diameter divergent magnetic field ion thruster, developed for mercury operation at 2.7 kW, was modified and operated with xenon propellant at a power level of 10 kW for 567 h to evaluate thruster performance and lifetime. The major differences between this thruster and its baseline configuration were elimination of the three mercury vaporizers, use of a main discharge cathode with a larger orifice, reduction in discharge baffle diameter, and use of an ion accelerating system with larger acceleration grid holes. Grid thickness measurement uncertainties, combined with estimates of the effects of reactive residual facility background gases gave a minimum screen grid lifetime of 7000 h. Discharge cathode orifice erosion rates were measured with three different cathodes with different initial orifice diameters. Three potential problems were identified during the wear test: the upstream side of the discharge baffle eroded at an unacceptable rate; two of the main cathode tubes experienced oxidation, deformation, and failure; and the accelerator grid impingement current was more than an order of magnitude higher than that of the baseline mercury thruster. The charge exchange ion erosion was not quantified in this test. There were no measurable changes in the accelerator grid thickness or the accelerator grid hole diameters.

Rawlin, Vincent K.↗

Internal erosion rates of a 10-kW xenon ion thruster

A 30 cm diameter divergent magnetic field ion thruster, developed for mercury operation at 2.7 kW, was modified and operated with xenon propellant at a power level of 10 kW for 567 h to evaluate thruster performance and lifetime. The major differences between this thruster and its baseline configuration were elimination of the three mercury vaporizers, use of a main discharge cathode with a larger orifice, reduction in discharge baffle diameter, and use of an ion accelerating system with larger acceleration grid holes. Grid thickness measurement uncertainties, combined with estimates of the effects of reactive residual facility background gases gave a minimum screen grid lifetime of 7000 h. Discharge cathode orifice erosion rates were measured with three different cathodes with different initial orifice diameters. Three potential problems were identified during the wear test: the upstream side of the discharge baffle eroded at an unacceptable rate; two of the main cathode tubes experienced oxidation, deformation, and failure; and the accelerator grid impingement current was more than an order of magnitude higher than that of the baseline mercury thruster. The charge exchange ion eroison was not quantified in this test. There were no measurable changes in the accelerator grid thickness or the accelerator grid hole diameters.

Rawlin, Vincent K.↗

Station keeping strategy for multiple spacecraft interferometry

The feasibility of multiple spacecraft stationkeeping for submillimeter and optical interferometry is examined. A condition for interferometry is that two or more spacecraft must control their relative positions with better than 1 mn accuracy indefinitely in both radial and transverse directions although separated by as much as 1 Km in LEO and 100 Km in GEO. They must also maneuver through a useful area of the U-V plane of an arbitrary astronomical source. The problem is first outlined and a solution which utilizes gravity gradient forces to do most of the work and ion thrusters for additional maneuvering is proposed. All the perturbing forces are shown to be small compared to the ion thruster requirements. An inertial position and attitude control strategy is suggested which utilizes existing or soon to be available sensors and actuators. Finally, the fuel and power system mass requirements are estimated and found to be within reason for a 10 year mission.

Decou, Anthony B.↗

A simple attitude data filter for three-axis attitude initialization for autonomous ascent of Shuttle-launched spacecraft

A method for accurately initializing spacecraft attitude after release from the Orbiter is described. It is noted that the method is suitable for an autonomous ascent to mission orbit. Test results are given from a FORTRAN simulation of the estimation algorithm using measurement data from a detailed spacecraft dynamics simulation program. The technique here is orbital yaw-gyrocompassing. Attitude is estimated through a Kalman filter, using pitch and roll measurements from an earth sensor, while gyro data provide the system dynamics information. In the tests described, gyro and earth sensor data are generated by an existing control system simulation of earth-search and yaw-gyrocompassing attitude dynamics; they include realistic errors such as delays, random noise and quantization effects. The estimated attitude history is compared with the true attitude history from the simulation program to assess the accuracy and convergence of the filter in the presence of noisy measurements and disturbances, including thruster firings for momentum control. It is noted that since the earth sensor provides direct measurements of pitch and roll, the main criterion of filter performance is yaw accuracy.

Joshi, R. T.↗

Effect of aerodynamic and angle-of-attack uncertainties on the May 1979 entry flight control system of the Space Shuttle from Mach 8 to 1.5

A six degree of freedom simulation analysis was performed for the space shuttle orbiter during entry from Mach 8 to Mach 1.5 with realistic off nominal conditions by using the flight control systems defined by the shuttle contractor. The off nominal conditions included aerodynamic uncertainties in extrapolating from wind tunnel derived characteristics to full scale flight characteristics, uncertainties in the estimates of the reaction control system interaction with the orbiter aerodynamics, an error in deriving the angle of attack from onboard instrumentation, the failure of two of the four reaction control system thrusters on each side, and a lateral center of gravity offset coupled with vehicle and flow asymmetries. With combinations of these off nominal conditions, the flight control system performed satisfactorily. At low hypersonic speeds, a few cases exhibited unacceptable performances when errors in deriving the angle of attack from the onboard instrumentation were modeled. The orbiter was unable to maintain lateral trim for some cases between Mach 5 and Mach 2 and exhibited limit cycle tendencies or residual roll oscillations between Mach 3 and Mach 1. Piloting techniques and changes in some gains and switching times in the flight control system are suggested to help alleviate these problems.

Stone, H. W.↗

Computational Modeling of NEXT 2000-Hour Wear Test Results

Ion optics computational models are invaluable tools for the design of ion optics systems. In this study, a new computational model developed by an outside vendor for NASA Glenn Research Center (GRC) is presented. This model is a gun code which has been modified to model the plasma sheaths both upstream and downstream of the ion optics. The model handles multiple species (e.g. singly and doubly-charged ions) and includes a charge-exchange model for erosion estimates. The model uses commercially available solid design and meshing software, allowing high flexibility in ion optics geometric configurations. This computational model is compared to experimental results from the NASA Evolutionary Xenon Thruster (NEXT) 2000-hour wear test, including over-focusing along the edge apertures, pit-and-groove erosion due to charge exchange, and beamlet distortion at the edge of the hole pattern.

Malone, Shane P.↗

Guide to Flow Measurement for Electric Propulsion Systems

In electric propulsion (EP) systems, accurate measurement of the propellant mass flow rate of gas or liquid to the thruster and external cathode is a key input in the calculation of thruster efficiency and specific impulse. Although such measurements are often achieved with commercial mass flow controllers and meters integrated into propellant feed systems, the variability in potential propellant options and flow requirements amongst the spectrum of EP power regimes and devices complicates meter selection, integration, and operation. At the direction of the Committee on Standards for Electric Propulsion Testing, a guide was jointly developed by members of the electric propulsion community to establish a unified document that contains the working principles, methods of implementation and analysis, and calibration techniques and recommendations on the use of mass flow meters in laboratory and spacecraft electric propulsion systems. The guide is applicable to EP devices of all types and power levels ranging from microthrusters to high-power ion engines and Hall effect thrusters. The establishment of a community standard on mass flow metering will help ensure the selection of the proper meter for each application. It will also improve the quality of system performance estimates by providing comprehensive information on the physical phenomena and systematic errors that must be accounted for during the analysis of flow measurement data. This paper will outline the standard methods and recommended practices described in the guide titled "Flow Measurement for Electric Propulsion Systems."

spacecraft electric propulsion (EP) systems↗

Drag-Free Control and Drag Force Recovery of Small Satellites

Drag-free satellites provide autonomous precision orbit determination, accurately map the static and time varying components of Earth's mass distribution, aid in our understanding of the fundamental force of gravity, and will ultimately open up a new window to our universe through the detection and observation of gravitational waves. At the heart of this technology is a gravitational reference sensor, which (a) contains and shields a free-floating proof mass from all non-gravitational forces, and (b) precisely measures the position of the test mass inside the sensor. Thus, both test mass and spacecraft follow a pure geodesic in spacetime. By tracking the position of a low Earth orbiting drag-free satellite we can directly determine the detailed shape of geodesics and through analysis, the higher order harmonics of the Earths geopotential. This paper explores two different drag-free control systems on small satellites. The first drag-free control system is a continuously compensated single thruster 3-unit CubeSat with a suspension-free spherical proof-mass. A feedback control system commands the thruster and Attitude and Determination Control System to fly the tender spacecraft with respect to the test mass. The spheres position is sensed with a LED-based differential optical shadow sensor, its electric charge controlled by photoemission using UV LEDs, and the spacecraft position is maintained with respect to the sphere using an ion electrospray propulsion system. This configuration is the most fuel-efficient drag-free system possible today. The second drag-free control system is an electro-statically suspended cubical proof-mass that is operated with a low duty cycle, limiting suspension force noise over brief, known time intervals on a small GRACE-II -like satellite. The readout is performed using a laser interferometer, which is immune to the dynamic range limitations of voltage references. This system eliminates the need for a thruster, enabling drag-free control systems for passive satellites. In both cases, the test mass position, GPS tracking data, and commanded actuation, either thrust or suspension system, can be analyzed to estimate the 3-axis drag forces acting on the satellite. The data produces the most precise maps of upper atmospheric drag forces and with additional information, detailed models that describe the dynamics of the upper atmosphere and its impact on all satellites that orbit the Earth. This paper highlights the history, applications, design, laboratory technology development and highly detailed simulation results of each control system.

Small Satellites↗

Design and Performance of 40 cm Ion Optics

A 40 cm ion thruster is being developed at the NASA Glenn Research Center to obtain input power and propellant throughput capabilities of 10 kW and 550 kg. respectively. The technical approach here is a continuation of the "derating" technique used for the NSTAR ion thruster. The 40 cm ion thruster presently utilizes the NSTAR ion optics aperture geometry to take advantage of the large database of lifetime and performance data already available. Dome-shaped grids were chosen for the design of the 40 cm ion optics because this design is naturally suited for large-area ion optics. Ion extraction capabilities and electron backstreaming limits for the 40 cm ion optics were estimated by utilizing NSTAR 30 cm ion optics data. A preliminary service life assessment showed that the propellant throughput goal of 550 kg of xenon may be possible with molybdenum 40 cm ion optics. One 40 cm ion optics' set has been successfully fabricated to date. Additional ion optics' sets are presently being fabricated. Preliminary performance tests were conducted on a laboratory model 40 cm ion thruster.

Soulas, George C.↗

Comparative Analysis of Static and Dynamic Probabilistic Risk Assessment

This study examines three different methodologies for producing loss-of-mission (LOM) and loss-of-crew (LOC) risks estimates for probabilistic risk assessments (PRA) of crewed spacecraft. The three bottom-up, component-based PRA approaches examined are a traditional static fault tree, a dynamic Monte Carlo simulation, and a fault tree hybrid that incorporates some dynamic elements. These approaches were used to model the reaction control system thruster pod of a generic crewed spacecraft and mission, and a comparative analysis of the methods is presented. The methodologies are assessed in terms of the process of modeling a system, the actionable information produced for the design team, and the overall fidelity of the quantitative risk evaluation generated. The system modeling process is compared in terms of the effort required to generate the initial model, update the model in response to design changes, and support mass-versus-risk trade studies. The results are compared by examining the top-level LOM/LOC estimates and the relative risk driver rankings at the failure mode level. The fidelity of each modeling methodology is discussed in terms of its capability to handle real-world system dynamics such as cold-sparing, changes in mission operations due to loss of redundancy, and common cause failure modes. The paper also discusses the applicability of each methodology to different phases of system development and shows that a single methodology may not be suitable for all of the many purposes of a spacecraft PRA. The fault tree hybrid approach is shown to be best suited to the needs of early assessments during conceptual design phases. As the design begins to mature, the level of detail represented in the risk model must go beyond redundancy and nominal mission operations to include dynamic, time- and state-dependent system responses as well as diverse system capabilities. This is best accomplished using the dynamic simulation approach, since these phenomena are not easily captured by static methods. Ultimately, once the design has been finalized and the goal of the PRA is to provide design validation and requirement verification, more traditional, static fault tree approaches may become as appropriate as the simulation method.

Mattenberger, Christopher J.↗

Modeling non-gravitational forces acting on TOPEX/POSEIDON: The early days

TOPEX/POSEIDON is a satellite mission that will use altimetry to make precise measurements of sea-level. The principal goal is to measure sea-level with unprecedented accuracy such that small-amplitude, basin wide sea-level changes caused by large-scale ocean circulation can be detected. To reach this goal, the sensor system and orbit must measure sea-level with decimeter accuracy. This requires that the radial component of the orbit be known to the decimeter level. Orbital errors are dominated by mismodelled gravitational and non-gravitational forces. This paper presents our analysis of non-gravitational forces acting on the satellite during the early days of the mission. Studies were conducted by comparing direct estimates of these forces with observed perturbations in the mean orbital elements. The results show that the satellite is experiencing an unexpected along-track acceleration. Hypotheses range from out-gassing to thruster leaks and drag forces to radiative force. Currently, these issues have not been resolved; however, the evidence suggests that out-gassing was dominant during the first weeks of the mission and that thermal imbalances persist.

Christensen, E. J.↗

PPT Thrust Stand

A torsional-type thrust stand has been designed and built to test Pulsed Plasma Thrusters (PPT's) in both single shot and repetitive operating modes. Using this stand, momentum per pulse was determined strictly as a function of thrust stand deflection, spring constant, and natural frequency. No empirical corrections were required. The accuracy of the method was verified using a swinging impact pendulum. Momentum transfer data between the thrust stand and the pendulum were consistent to within 1%. Following initial calibrations, the stand was used to test a Lincoln Experimental Satellite (LES-8/9) thruster. The LES-8/9 system had a mass of approximately 7.5 kg, with a nominal thrust to weight ratio of 1.3 x 10(exp -5). A total of 34 single shot thruster pulses were individually measured. The average impulse bit per pulse was 266 microN-s, which was slightly less than the value of 300 microN-s published in previous reports on this device. Repetitive pulse measurements were performed similar to ordinary steady-state thrust measurements. The thruster was operated for 30 minutes at a repetition rate of 132 pulses per minute and yielded an average thrust of 573 microN. Using average thrust, the average impulse bit per pulse was estimated to be 260 microN-s, which was in agreement with the single shot data. Zero drift during the repetitive pulse test was found to be approximately 1% of the measured thrust.

Haag, Thomas W.↗

The effect of atmospheric drag on the design of solar-cell power systems for low Earth orbit

The feasibility of reducing the atmospheric drag of low orbit solar powered satellites by operating the solar-cell array in a minimum-drag attitude, rather than in the conventional Sun pointing attitude was determined. The weights of the solar array, the energy storage batteries, and the fuel required to overcome the drag of the solar array for a range of design life times in orbit were considered. The drag of the array was estimated by free molecule flow theory, and the system weights were calculated from unit weight estimates for 1990 technology. The trailing, minimum drag system was found to require 80% more solar array area, and 30% more battery capacity, the system weights for reasonable life times were dominated by the thruster fuel requirements.

Kyser, A. C.↗

High-Performance, Space-Storable, Bi-Propellant Program Status

Bipropellant propulsion systems currently represent the largest bus subsystem for many missions. These missions range from low Earth orbit satellite to geosynchronous communications and planetary exploration. The payoff of high performance bipropellant systems is illustrated by the fact that Aerojet Redmond has qualified a commercial NTO/MMH engine based on the high Isp technology recently delivered by this program. They are now qualifying a NTO/hydrazine version of this engine. The advanced rhenium thrust chambers recently provided by this program have raised the performance of earth storable propellants from 315 sec to 328 sec of specific impulse. The recently introduced rhenium technology is the first new technology introduced to satellite propulsion in 30 years. Typically, the lead time required to develop and qualify new chemical thruster technology is not compatible with program development schedules. These technology development programs must be supported by a long term, Base R&T Program, if the technology s to be matured. This technology program then addresses the need for high performance, storable, on-board chemical propulsion for planetary rendezvous and descent/ascent. The primary NASA customer for this technology is Space Science, which identifies this need for such programs as Mars Surface Return, Titan Explorer, Neptune Orbiter, and Europa Lander. High performance (390 sec) chemical propulsion is estimated to add 105% payload to the Mars Sample Return mission or alternatively reduce the launch mass by 33%. In many cases, the use of existing (flight heritage) propellant technology is accommodated by reducing mission objectives and/or increasing enroute travel times sacrificing the science value per unit cost of the program. Therefore, a high performance storable thruster utilizing fluorinated oxidizers with hydrazine is being developed.

Schneider, Steven J.↗

Stardust Navigation Covariance Analysis

The Stardust spacecraft was launched on February 7, 1999 aboard a Boeing Delta-II rocket. Mission participants include the National Aeronautics and Space Administration (NASA), the Jet Propulsion Laboratory (JPL), Lockheed Martin Astronautics (LMA) and the University of Washington. The primary objective of the mission is to collect in-situ samples of the coma of comet Wild-2 and return those samples to the Earth for analysis. Mission design and operational navigation for Stardust is performed by the Jet Propulsion Laboratory (JPL). This paper will describe the extensive JPL effort in support of the Stardust pre-launch analysis of the orbit determination component of the mission covariance study. A description of the mission and it's trajectory will be provided first, followed by a discussion of the covariance procedure and models. Predicted accuracy's will be examined as they relate to navigation delivery requirements for specific critical events during the mission. Stardust was launched into a heliocentric trajectory in early 1999. It will perform an Earth Gravity Assist (EGA) on January 15, 2001 to acquire an orbit for the eventual rendezvous with comet Wild-2. The spacecraft will fly through the coma (atmosphere) on the dayside of Wild-2 on January 2, 2004. At that time samples will be obtained using an aerogel collector. After the comet encounter Stardust will return to Earth when the Sample Return Capsule (SRC) will separate and land at the Utah Test Site (UTTR) on January 15, 2006. The spacecraft will however be deflected off into a heliocentric orbit. The mission is divided into three phases for the covariance analysis. They are 1) Launch to EGA, 2) EGA to Wild-2 encounter and 3) Wild-2 encounter to Earth reentry. Orbit determination assumptions for each phase are provided. These include estimated and consider parameters and their associated a-priori uncertainties. Major perturbations to the trajectory include 19 deterministic and statistical maneuvers planned for the mission. The spacecraft is three axis stabilized and has unbalanced thrusters for attitude control. Accelerations due to the attitude control system are treated stochastically. The tracking scenario for the study is patterned after the actual schedule employed during the different phases of the mission. Conventional X-band two-way Doppler and SRA range data was simulated and the standard accuracy for these data types was assumed throughout most of the mission. However, a deweighting scheme was used for the Doppler data during times of low Sun-Earth-Probe angles, especially in the case of the DSM. Optical data is assumed to be available starting at 50 days prior to the comet encounter. The optical data will be used to improve the ephemeris of Wild-2, which is considered crucial to properly target the comet flyby. Results of the covariance analysis are presented for all mission phases. Navigation capability will be discussed in terms of the uncertainty in the encounter B-Plane (B.R and B.T) and linearized time of flight. Delivery errors based on the final maneuver prior to the comet encounter will be presented. The most stringent navigation requirement is for the Earth reentry. The uncertainty in the flight path angle must be less than 0.02 degree (orbit determination and maneuver performance) to assure successful recovery of the SRC. Results presented show that this requirement can be met.

Menon, Premkumar R.↗

NASA Tech Briefs, March 2006

Topics covered include: Medical Signal-Conditioning and Data-Interface System; Instruments for Reading Direct-Marked Data-Matrix Symbols; Processing EOS MLS Level-2 Data; Ground Processing of Data From the Mars Exploration Rovers; Estimating Total Electron Content Using 1,000+ GPS Receivers; NASA Solar Array Demonstrates Commercial Potential; Improved Control of Charging Voltage for Li-Ion Battery; Programmable Pulse-Position-Modulation Encoder; Wavelength-Agile External-Cavity Diode Laser for DWDM; Pattern-Recognition Processor Using Holographic Photopolymer; Submicrosecond Power-Switching Test Circuit; Three-Function Logic Gate Controlled by Analog Voltage; Integrated System for Autonomous Science; Montage Version 3.0; Utilizing AI in Temporal, Spatial, and Resource Scheduling; Satellite Image Mosaic Engine; Architecture for Control of the K9 Rover; HFGMC Enhancement of MAC/GMC; Automated Activation and Deactivation of a System Under Test; Cleaning Carbon Nanotubes by Use of Mild Oxygen Plasmas; Generating Aromatics From CO2 on Mars or Natural Gas on Earth; Attaching Thermocouples by Peening or Crimping; Heat Treatment of Friction-Stir-Welded 7050 Aluminum Plates; Generating Breathable Air Through Dissociation of N2O; High-Performance Scanning Acousto-Ultrasonic System; Correction for Thermal EMFs in Thermocouple Feedthroughs; Using Quasiparticle Poisoning To Detect Photons; Estimating Resolution Lengths of Hybrid Turbulence Models; Education and Training Module in Alertness Management; Cargo-Positioning System for Next-Generation Spacecraft; Micro-Imagers for Spaceborne Cell-Growth Experiments; Holographic Solar Photon Thrusters; Plasma-Based Detector of Outer-Space Dust Particles; and Generation of Data-Rate Profiles of Ka-Band Deep-Space Links.

Source record↗

Pinhole-coronograph tracking control

The pinhole occulter system, a space shuttle based experiment for the production of hard X-ray images taken primarily from the Sun is described. The system is a pinhole camera utilizing a deployable 50 m flexible boom for separating the pinhole from the recording devices located in the shuttle. The system is subjected to the disturbances of the shuttle. The worst of these are thruster firing for orbit correction, man motion, motion induced by other systems, and gravity gradient torques. The control system of the pointing mount senses both position and velocity of the mask tip and uses these to estimate accurately the flexible modes of the system.

Greene, M.↗