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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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Advancing the practice of systems engineering at JPL

In FY 2004, JPL launched an initiative to improve the way it practices systems engineering. The Lab's senior management formed the Systems Engineering Advancement (SEA) Project in order to "significantly advance the practice and organizational capabilities of systems engineering at JPL on flight projects and ground support tasks." The scope of the SEA Project includes the systems engineering work performed in all three dimensions of a program, project, or task: 1. the full life-cycle, i.e., concept through end of operations 2. the full depth, i.e., Program, Project, System, Subsystem, Element (SE Levels 1 to 5) 3. the full technical scope, e.g., the flight, ground and launch systems, avionics, power, propulsion, telecommunications, thermal, etc. The initial focus of their efforts defined the following basic systems engineering functions at JPL: systems architecture, requirements management, interface definition, technical resource management, system design and analysis, system verification and validation, risk management, technical peer reviews, design process management and systems engineering task management, They also developed a list of highly valued personal behaviors of systems engineers, and are working to inculcate those behaviors into members of their systems engineering community. The SEA Project is developing products, services, and training to support managers and practitioners throughout the entire system lifecycle. As these are developed, each one needs to be systematically deployed. Hence, the SEA Project developed a deployment process that includes four aspects: infrastructure and operations, communication and outreach, education and training, and consulting support. In addition, the SEA Project has taken a proactive approach to organizational change management and customer relationship management - both concepts and approaches not usually invoked in an engineering environment. This paper'3 describes JPL's approach to advancing the practice of systems engineering at the Lab. It describes the general approach used and how they addressed the three key aspects of change: people, process and technology. It highlights a list of highly valued personal behaviors of systems engineers, discusses the various products, services and training that were developed, describes the deployment approach used, and concludes with several lessons learned.

process improvement↗

Spacecraft Testing Programs: Adding Value to the Systems Engineering Process

Testing has long been recognized as a critical component of spacecraft development activities - yet many major systems failures may have been prevented with more rigorous testing programs. The question is why is more testing not being conducted? Given unlimited resources, more testing would likely be included in a spacecraft development program. Striking the right balance between too much testing and not enough has been a long-term challenge for many industries. The objective of this paper is to discuss some of the barriers, enablers, and best practices for developing and sustaining a strong test program and testing team. This paper will also explore the testing decision factors used by managers; the varying attitudes toward testing; methods to develop strong test engineers; and the influence of behavior, culture and processes on testing programs. KEY WORDS: Risk, Integration and Test, Validation, Verification, Test Program Development

Britton, Keith J.↗

Testing and Analytical Modeling for Purging Process of a Cryogenic Line

To gain confidence in developing analytical models of the purging process for the cryogenic main propulsion systems of upper stage, two test series were conducted. Test article, a 3.35m long with the diameter of 20 cm incline line, was filled with liquid (LH2)or gaseous hydrogen (GH2) and then purged with gaseous helium (GHe). Total of 10 tests were conducted. Influences of GHe flow rates and initial temperatures were evaluated. Generalized Fluid System Simulation Program (GFSSP), an in-house general-purpose fluid system analyzer, was utilized to model and simulate selective tests.

Hedayat, A.↗

Cumulus: NASA's Cloud Based Distributed Active Archive Center Prototype

NASAs Earth Science Data System (ESDS) Program serves as a central cog in order to facilitate the implementation of NASA's Earth Science strategic plan. Since 1994, the ESDS Program has committed to the full and open sharing of Earth science data obtained from NASA instruments to all users. One of the key responsibilities of the ESDS Program is to continuously evolve the entire data and information system to maximize returns on the collected NASA data. An independent review was conducted in 2015 to holistically review the EOSDIS in order to identify gaps. The review recommendations were to investigate two areas: one, whether commercial cloud providers offer potential for storage, processing, and operational efficiencies, and two, the potential development of new data access and analysis paradigms. In response, ESDS has initiated several prototypes investigating the advantages and risks of leveraging cloud computing. This paper describes one such prototyping activity named Cumulus. Cumulus is being designed and developed as a "native" cloud-based data ingest, archive and management system that can be used for all future NASA Earth science data streams. Cumulus will foster design of new analysisvisualization tools that can leverage collocated data from all of the distributed DAACs as well as elastic cloud computing resources.

Earth Science Informatics↗

NASA’s Initial and Sustained Artemis Human Landing Systems

On March 26, 2019, in keeping with President Trump’s Space Policy Directive-1, Vice President Pence charged NASA with landing the first woman and the next man on the South Pole of the Moon by 2024, followed by a sustained presence on and around the Moon by 2028. NASA’s Human Landing System (HLS) Program is responsible for the final mode of transportation in deep space that will carry humans to and from the surface of the Moon, to be designed and developed by American companies for NASA’s Artemis lunar exploration program. This paper examines the approach for Artemis human landing systems for both the initial missions and future sustained missions. While achieving the 2024 goal requires a focus on speed and the use of mature technologies, planning toward sustained operations to and from the lunar surface requires a focus on reliability and reusability. The two approaches, however, are not mutually exclusive, as demonstrated by the HLS prime contractors’ integrated lander system proposals. On April 30, 2020, NASA announced that Blue Origin of Kent, Washington, Dynetics (a Leidos company) of Huntsville, Alabama, and SpaceX of Hawthorne, California, were the awardees for NASA’s Human Landing System contracts under Appendix H of the NextSTEP-2 Broad Agency Announcement. The companies began work in a 10-month base period during which NASA teams worked with the companies to streamline the review of required products and to share the agency’s expertise in human spaceflight systems development. Following the base period, NASA will determine which company or companies will develop the human landers for the initial missions, including the 2024 landing, and which companies will develop landers for future sustained missions toward the end of the decade.

HLS↗

NASA's Initial and Sustained Artemis Human Landing Systems

On March 26, 2019, in keeping with President Trump’s Space Policy Directive-1, Vice President Pence charged NASA with landing the first woman and the next man on the South Pole of the Moon by 2024, followed by a sustained presence on and around the Moon by2028. NASA’s Human Landing System (HLS) Program is responsible for the final mode of transportation in deep space that will carry humans to and from the surface of the Moon, to be designed and developed by American companies for NASA’s Artemis lunar exploration program. This paper examines the approach for Artemis human landing systems for both the initial missions and future sustained missions. While achieving the 2024 goal requires a focus on speed and the use of mature technologies, planning toward sustained operations to and from the lunar surface requires a focus on reliability and reusability. The two approaches, however, are not mutually exclusive, as demonstrated by the HLS prime contractors’ integrated lander system proposals. On April 30, 2020, NASA announced that Blue Origin of Kent, Washington, Dynetics (a Leidos company) of Huntsville, Alabama, and SpaceX of Hawthorne, California, were the awardees for NASA’s Human Landing System contracts under Appendix H of the NextSTEP-2 Broad Agency Announcement. The companies began work in a 10-month base period during which NASA teams worked with the companies to streamline the review of required products and to share the agency’s expertise in human spaceflight systems development. Following the base period, NASA will determine which companies will develop the human landers for the initial missions, including the 2024 landing, and which companies will develop landers for future sustained missions toward the end of the decade.

Lisa Watson-Morgan↗

Operating System For Numerically Controlled Milling Machine

OPMILL program is operating system for Kearney and Trecker milling machine providing fast easy way to program manufacture of machine parts with IBM-compatible personal computer. Gives machinist "equation plotter" feature, which plots equations that define movements and converts equations to milling-machine-controlling program moving cutter along defined path. System includes tool-manager software handling up to 25 tools and automatically adjusts to account for each tool. Developed on IBM PS/2 computer running DOS 3.3 with 1 MB of random-access memory.

Ray, R. B.↗

Direct Imaging and Spectroscopy of Exoplanetary Systems with the JWST Early Release Science Program

The direct characterization of exoplanetary systems with high contrast imaging is among the highest priorities for the broader exoplanet community. As large space missions will be necessary for detecting and characterizing exo-Earth twins, developing the techniques and technology for direct imaging of exoplanets is a driving focus for the community. For the first time, JWST will directly observe extrasolar planets at mid-infrared wavelengths beyond 5 μm, deliver detailed spectroscopy revealing much more precise chemical abundances and atmospheric conditions, and provide sensitivity to analogs of our solar system ice-giant planets at wide orbital separations, an entirely new class of exoplanet. However, in order to maximise the scientific output over the lifetime of the mission, an exquisite understanding of the instrumental performance of JWST is needed as early in the mission as possible. In this paper, we describe our 55-hour Early Release Science Program that will utilize all four JWST instruments to extend the characterisation of planetary mass companions to ∼15-20 μm as well as image a circumstellar disk in the mid-infrared with unprecedented sensitivity. Our program will also assess the performance of the observatory in the key modes expected to be commonly used for exoplanet direct imaging and spectroscopy, optimize data calibration and processing, and generate representative datasets that will enable a broad user base to effectively plan for general observing programs in future cycles.

Michael W McElwain↗

Program Aids Design Of Fluid-Circulating Systems

Computer Aided Systems Engineering and Analysis (CASE/A) program is interactive software tool for trade study and analysis, designed to increase productivity during all phases of systems engineering. Graphics-based command-driven software package provides user-friendly computing environment in which engineer analyzes performance and interface characteristics of ECLS/ATC system. Useful during all phases of spacecraft-design program, from initial conceptual design trade studies to actual flight, including pre-flight prediction and in-flight analysis of anomalies. Written in FORTRAN 77.

Bacskay, Allen↗

SSME to RS-25: Challenges of Adapting a Heritage Engine to a New Vehicle Architecture

Following the cancellation of the Constellation program and retirement of the Space Shuttle, NASA initiated the Space Launch System (SLS) program to provide next-generation heavy lift cargo and crew access to space. A key constituent of the SLS architecture is the RS-25 engine, also known as the Space Shuttle Main Engine (SSME). The RS-25 was selected to serve as the main propulsion system for the SLS core stage in conjunction with the solid rocket boosters. This selection was largely based on the maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. However, while the RS-25 is a highly mature system, simply unbolting it from the Space Shuttle boat-tail and installing it on the new SLS vehicle is not a "plug-and-play" operation. In addition to numerous technical integration details involving changes to significant areas such as the environments, interface conditions, technical performance requirements, operational constraints and so on, there were other challenges to be overcome in the area of replacing the obsolete engine control system (ECS). While the magnitude of accomplishing this effort was less than that needed to develop and field a new clean-sheet engine system, the path to the first flight of SLS has not been without unexpected challenges.

Ballard, Richard O.↗

Ascent air data system results from the space shuttle flight test program

The ascent air data system of the Space Shuttle consists of a simple biconic spike probe on the nose of the external tank. Pressure measurements were calibrated in a wind tunnel to obtain vehicle attitude and speed (relative to the air) and dynamic pressure. The wind tunnel test data analysis and the calibration are discussed in terms of test problems and calibration parameter formulation. The flight pressures are traced from telemetry data to final air data products. Analysis of the flight results showed that static pressure could not be accurately determined at the higher Mach numbers (above approx. 2.0). By replacing static pressure with data from a postflight estimated trajectory the ascent air data system performance met the user requirements. Lessons learned are enumerated, the most important being the need for a thorough systems integration effort.

Hillje, E. R.↗

Electrochemical air revitalization system optimization investigation

A program to characterize a Breadboard of an Electrochemical Air Revitalization System (BEARS) was successfully completed. The BEARS is composed of three components: (1) a water vapor electrolysis module (WVEM) for O2 production and partial humidity control, (2) an electrochemical depolarized carbon dioxide concentrator module (EDCM) for CO2 control, and (3) a power-sharing controller, designed to utilize the power produced by the EDCM to partially offset the WVEM power requirements. It is concluded from the results of this work that the concept of electrochemical air revitalization with power-sharing is a viable solution to the problem of providing a localized topping force for O2 generation, CO2 removal and partial humidity control aboard manned spacecraft. Continued development of the EARS concept is recommended, applying the operational experience and limits identified during the BEARS program to testing of a one-man capacity system and toward the development of advanced system controls to optimize EARS operation for given interfaces and requirements. Successful completion of this development will produce timely technology necessary to plan future advanced environmental control and life support system programs and experiments.

Woods, R. R.↗

Electro-Mechanical Actuator. DC Resonant Link Controller

This report summarizes the work performed on the 68 HP electro-mechanical actuator (EMA) system developed on NASA contract for the Electrical Actuation (ELA) Technology Bridging Program. The system was designed to demonstrate the capability of large, high power linear ELAs for applications such as Thrust Vector Control (TVC) on rocket engines. It consists of a motor controller, drive electronics and a linear actuator capable of up to 32,00 lbs loading at 7.4 inches/second. The drive electronics are based on the Resonant DC link concept and operate at a nominal frequency of 55 kHz. The induction motor is a specially designed high speed, low inertia motor capable of a 68 peak HP. The actuator was originally designed by MOOG Aerospace under an internal R & D program to meet Space Shuttle Main Engine (SSME) TVC requirements. The design was modified to meet this programs linear rate specification of 7.4 inches/second. The motor and driver were tested on a dynamometer at the Martin Marietta Space Systems facility. System frequency response, step response and force-velocity tests were conducted at the MOOG Aerospace facility. A complete description of the system and all test results can be found in the body of the report.

Schreiner, Kenneth E.↗

Systems Engineering and Integration for Technology Programs

The Architecture, Habitability & Integration group (AH&I) is a system engineering and integration test team within the NASA Crew and Thermal Systems Division (CTSD) at Johnson Space Center. AH&I identifies and resolves system-level integration issues within the research and technology development community. The timely resolution of these integration issues is fundamental to the development of human system requirements and exploration capability. The integration of the many individual components necessary to construct an artificial environment is difficult. The necessary interactions between individual components and systems must be approached in a piece-wise fashion to achieve repeatable results. A formal systems engineering (SE) approach to define, develop, and integrate quality systems within the life support community has been developed. This approach will allow a Research & Technology Program to systematically approach the development, management, and quality of technology deliverables to the various exploration missions. A tiered system engineering structure has been proposed to implement best systems engineering practices across all development levels from basic research to working assemblies. These practices will be implemented through a management plan across all applicable programs, projects, elements and teams. While many of the engineering practices are common to other industries, the implementation is specific to technology development. An accounting of the systems engineering management philosophy will be discussed and the associated programmatic processes will be presented.

Kennedy, Kruss J.↗

System Safety in Early Manned Space Program: A Case Study of NASA and Project Mercury

This case study provides a review of National Aeronautics and Space Administration s (NASA's) involvement in system safety during research and evolution from air breathing to exo-atmospheric capable flight systems culminating in the successful Project Mercury. Although NASA has been philosophically committed to the principals of system safety, this case study points out that budget and manpower constraints-as well as a variety of internal and external pressures can jeopardize even a well-designed system safety program. This study begins with a review of the evolution and early years of NASA's rise as a project lead agency and ends with the lessons learned from Project Mercury.

Hansen, Frederick D.↗

New 5 Kilowatt Free-piston Stirling Space Convertor Developments

The NASA Vision for Exploration of the moon may someday require a nuclear reactor coupled with a free-piston Stirling convertor at a power level of 30-40 kW. In the 1990s, Mechanical Technology Inc. s Stirling Engine Systems Division (some of whose Stirling personnel are now at Foster-Miller, Inc.) developed a 25 kW free piston Stirling Space Power Demonstrator Engine under the SP-100 program. This system consisted of two 12.5 kW engines connected at their hot ends and mounted in tandem to cancel vibration. Recently, NASA and DoE have been developing dual 55 W and 80 W Stirling convertor systems for potential use with radioisotope heat sources. Total test times of all convertors in this effort exceed 120,000 hours. Recently, NASA began a new project with Auburn University to develop a 5 kW, single convertor for potential use in a lunar surface reactor power system. Goals of this development program include a specific power in excess of 140 W/kg at the convertor level, lifetime in excess of five years and a control system that will safely manage the convertors in case of an emergency. Auburn University awarded a subcontract to Foster-Miller, Inc. to undertake development of the 5 kW Stirling Convertor Assembly. The characteristics of the design along with progress in developing the system will be described.

Brandhorst, Henry W., Jr.↗

The U.S.-NSF/NASA

The five-year research and development plan of the NSF/NASA Wind Energy Conversion Systems (WECS) program is outlined. The program includes mission studies to determine energy use patterns and requirements and define specific applications for wind energy systems, wind energy resource assessment and development, and development of cost-effective components and subsystems. The program is also directed towards the development of energy storage systems to make wind powered systems firm power sources where appropriate. A 100 kW experimental wind generator (Model Zero) is being designed as a flexible test bed for a variety of system components. Designs will be developed for units in the 50 to 200 kW and 500 to 3000 kW size ranges.

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