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NASA NTRS2022

Electrical Ground Support Equipment for the Sampling Caching System of the Mars 2020 Rover

In this work we describe in detail the architecture, design, testing and operation of the Electrical Ground Support Equipment (EGSE) “Blue Box” used to test and validate the Sampling Caching System (SCS) of the Mars 2020 Perseverance rover. The Blue Box architecture is centered around COTS motor controllers and COTS input-output modules communicating over an EtherCAT bus. A custom, low-level safety subsystem ensures no harm can be done to the flight articles. The modular architecture of the EGSE reduces cost and complexity while expediting assembly time. The Blue Box drives the 19 actuators of the SCS which span the main robotic arm, the corer system, the internal sample handling arm, the sample tube sealing system and the gas dust removal tool; mimicking the Rover Motor Control Assembly (RMCA). Due to the limited availability of RMCA’s, the EGSE enabled and performed the bulk of testing activities for SCS. The majority of the SCS actuators are composed of a 3-phase DC brushless motors, hall sensors for commutation, dual resolvers for output angular measurement, brakes, heaters and platinum thermistors. Additionally, the EGSE read 12 strain gauges forming part of a force torque sensor, and switches used for external positioning references. Over the 3-year span of the V&V campaign for the SCS, over 32 EGSE systems were built, tested and deployed to test venues at JPL and externally. The EGSE tested several families of the SCS subsystem, ranging from engineering units, life test units and two flight units. Test venues that this EGSE supported included lab benches, ultra-clean cleanrooms, ATLO facilities, and thermal vacuum chambers. Together with the test software systems, SSDEV and SSDEV-ECAT, the Blue Box EGSE enabled the team to efficiently test flight hardware and flight software together. We go over the safety features and fault management techniques employed to protect flight hardware. The effects of the long, 50-feet, EGSE harnesses on motor performance, EMI, electrical noise, and motor control performance are explained. Mitigations to these unwanted effects, including shielding strategy and inductance compensation, are summarized. We go over an excerpt of notable anomalies that this EGSE suffered through its operation, along with investigations and resolutions. Lessons learned, areas of improvement as part of future work, and recommendations for future implementations for similar EGSE’s, are shared.

Levine, Dan↗

NASA NTRS2011

Design and Analysis of Mirror Modules for IXO and Beyond

Advancements in X-ray astronomy demand thin, light, and closely packed thin optics which lend themselves to segmentation of the annular mirrors and, in turn, a modular approach to the mirror design. The functionality requirements of such a mirror module are well understood. A baseline modular concept for the proposed International X-Ray Observatory (IXO) Flight Mirror Assembly (FMA) consisting of 14,000 glass mirror segments divided into 60 modules was developed and extensively analyzed. Through this development, our understanding of module loads, mirror stress, thermal performance, and gravity distortion have greatly progressed. The latest progress in each of these areas is discussed herein. Gravity distortion during horizontal X-ray testing and on-orbit thermal performance have proved especially difficult design challenges. In light of these challenges, fundamental trades in modular X-ray mirror design have been performed. Future directions in module X-ray mirror design are explored including the development of a 1.8 m diameter FMA utilizing smaller mirror modules. The effect of module size on mirror stress, module self-weight distortion, thermal control, and range of segment sizes required is explored with advantages demonstrated from smaller module size in most cases.

McClelland, Ryan S.↗

NASA NTRS1999

Integrated Avionics System (IAS), Integrating 3-D Technology On A Spacecraft Panel

As spacecraft designs converge toward miniaturization, and with the volumetric and mass challenges placed on avionics, programs will continue to advance the "state of the art" in spacecraft system development with new challenges to reduce power, mass and volume. Traditionally, the trend is to focus on high-density 3-D packaging technologies. Industry has made significant progress in 3-D technologies, and other related internal and external interconnection schemes. Although new technologies have improved packaging densities, a system packaging architecture is required that not only reduces spacecraft volume and mass budgets, but increase integration efficiencies, provide modularity and flexibility to accommodate multiple missions while maintaining a low recurring cost. With these challenges in mind, a novel system packaging approach incorporates solutions that provide broader environmental applications, more flexible system interconnectivity, scalability, and simplified assembly test and integration schemes. The Integrated Avionics System (IAS) provides for a low-mass, modular distributed or centralized packaging architecture which combines ridged-flex technologies, high-density COTS hardware and a new 3-D mechanical packaging approach, Horizontal Mounted Cube (HMC). This paper will describe the fundamental elements of the IAS, HMC hardware design, system integration and environmental test results.

Hunter, Don J.↗

NASA NTRS1969

Study of a modular extravehicular activity work platform

Configurations for extravehicular activity work platforms for astronaut use in orbital assembly

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NASA NTRS2012

FACT, Mega-ROSA, SOLAROSA

The Flexible Array Concentrator Technology (FACT) is a lightweight, high-performance reflective concentrator blanket assembly that can be used on flexible solar array blankets. The FACT concentrator replaces every other row of solar cells on a solar array blanket, significantly reducing the cost of the array. The modular design is highly scalable for the array system designer, and exhibits compact stowage, good off-pointing acceptance, and mass/cost savings. The assembly s relatively low concentration ratio, accompanied by a large radiative area, provides for a low cell operating temperature, and eliminates many of the thermal problems inherent in high-concentration-ratio designs. Unlike other reflector technologies, the FACT concentrator modules function on both z-fold and rolled flexible solar array blankets, as well as rigid array systems. Mega-ROSA (Mega Roll-Out Solar Array) is a new, highly modularized and extremely scalable version of ROSA that provides immense power level range capability from 100 kW to several MW in size. Mega-ROSA will enable extremely high-power spacecraft and SEP-powered missions, including space-tug and largescale planetary science and lunar/asteroid exploration missions. Mega-ROSA's inherent broad power scalability is achieved while retaining ROSA s solar array performance metrics and missionenabling features for lightweight, compact stowage volume and affordability. This innovation will enable future ultra-high-power missions through lowcost (25 to 50% cost savings, depending on PV and blanket technology), lightweight, high specific power (greater than 200 to 400 Watts per kilogram BOL (beginning-of-life) at the wing level depending on PV and blanket technology), compact stowage volume (greater than 50 kilowatts per cubic meter for very large arrays), high reliability, platform simplicity (low failure modes), high deployed strength/stiffness when scaled to huge sizes, and high-voltage operation capability. Mega-ROSA is adaptable to all photovoltaic and concentrator flexible blanket technologies, and can readily accommodate standard multijunction and emerging ultra-lightweight IMM (inverted metamorphic) photovoltaic flexible blanket assemblies, as well as ENTECHs Stretched Lens Array (SLA) and DSSs (Deployable Space Systems) FACT, which allows for cost reduction at the array level.

Spence, Brian↗

NASA NTRS2010

NASA Docking System (NDS) Interface Definitions Document (IDD)

The NASA Docking System (NDS) mating system supports low approach velocity docking and provides a modular and reconfigurable standard interface, supporting crewed and autonomous vehicles during mating and assembly operations. The NDS is NASA's implementation for the emerging International Docking System Standard (IDSS) using low impact docking technology. All NDS configurations can mate with the configuration specified in the IDSS Interface Definition Document (IDD) released September 21, 2010. The NDS evolved from the Low Impact Docking System (LIDS). The acronym international Low Impact Docking System (iLIDS) is also used to describe this system. NDS and iLIDS may be used interchangeability. Some of the heritage documentation and implementations (e.g., software command names) used on NDS will continue to use the LIDS acronym. The NDS IDD defines the interface characteristics and performance capability of the NDS, including uses ranging from crewed to autonomous space vehicles and from low earth orbit to deep space exploration. The responsibility for developing space vehicles and for making them technically and operationally compatible with the NDS rests with the vehicle providers. Host vehicle examples include crewed/uncrewed spacecraft, space station modules, elements, etc. Within this document, any docking space vehicle will be referred to as the host vehicle. This document defines the NDS-to-NDS interfaces, as well as the NDS-to-host vehicle interfaces and performance capability.

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NASA NTRS2011

NASA Docking System (NDS) Interface Definitions Document (IDD)

Lewis, James↗

NASA NTRS2005

A Design of a Modular GPHS-Stirling Power System for a Lunar Habitation Module

Lunar habitation modules need electricity and potentially heat to operate. Because of the low amounts of radiation emitted by General Purpose Heat Source (GPHS) modules, power plants incorporating these as heat sources could be placed in close proximity to habitation modules. A design concept is discussed for a high efficiency power plant based on a GPHS assembly integrated with a Stirling convertor. This system could provide both electrical power and heat, if required, for a lunar habitation module. The conceptual GPHS/Stirling system is modular in nature and made up of a basic 5.5 KWe Stirling convertor/GPHS module assembly, convertor controller/PMAD electronics, waste heat radiators, and associated thermal insulation. For the specific lunar application under investigation eight modules are employed to deliver 40 KWe to the habitation module. This design looks at three levels of Stirling convertor technology and addresses the issues of integrating the Stirling convertors with the GPHS heat sources assembly using proven technology whenever possible. In addition, issues related to the high-temperature heat transport system, power management, convertor control, vibration isolation, and potential system packaging configurations to ensure safe operation during all phases of deployment will be discussed.

Schmitz, Paul C.↗

NASA NTRS1978

SIMS prototype system 4: Design data brochure

A pre-package prototype unit having domestic hot water and room solar heating capability that uses air as the collector fluid is described. This system is designed to be used with a small single-family dwelling where a roof mounted collector array is not feasible. The prototype unit is an assemble containing 203 square feet of effective collector surface with 113 cubic feet of rock storage. The design of structure and storage is modular, which permits expansion and reduction of the collector array and storage bed in 68 square feet and 37 cubic feet increments respectively. The system is designed to be transportable. This permitted assemble and certification testing in one area and installation in another area without tear down and reassemble. Design, installation, operation, performance and maintenance of this system are described.

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NASA NTRS1989

Initial characterization of a modular heat exchanger with an integral heat pipe

As part of the Civil Space Technology Initiative (CSTI) Advanced Technology program, a conceptual design of the Stirling space engine (SSE) was generated. The overall goal of the CSTI high capacity power element is to develop the technology base needed to meet the long duration, high capacity power requirements for future NASA space missions. The free-piston Stirling engine (FPSE) was chosen as the growth option in the CSTI program. A major goal during the conceptual design of the SSE was to reduce the number of critical joints. One area of concern was the heat exchanger assemblies that typically have the majority of critical joints. The solution proposed in the SSE conceptual design used 40 modular heat exchangers. Each module has its own integral heat pipe to transport heat from the heat source to the engine. A demonstration of the modular concept was undertaken before committing to the detailed design of the SSE heat exchangers. An existing FPSE was modified as a test bed for modular heat exchanger evaluation. The engine incorporated three heat exchanger modules, each having a sodium filled heat pipe. The thermal loading of these modules was intended to be similar to the conditions projected for the SSE modules. The engine was assembled and tests are underway. The design and fabrication of the heat exchanger modules and the engine used for these tests were described. Evaluation of the individual heat pipes before installation in the engine is described. The initial test results with the modules in operation on the engine were presented. Future tests involving the engine were outlined.

Schreiber, Jeffrey G.↗

NASA NTRS1977

Concept report: Microprocessor control of electrical power system

An electrical power system which uses a microprocessor for systems control and monitoring is described. The microprocessor controlled system permits real time modification of system parameters for optimizing a system configuration, especially in the event of an anomaly. By reducing the components count, the assembling and testing of the unit is simplified, and reliability is increased. A resuable modular power conversion system capable of satisfying a large percentage of space applications requirements is examined along with the programmable power processor. The PC global controller which handles systems control and external communication is analyzed, and a software description is given. A systems application summary is also included.

Perry, E.↗

NASA NTRS1982

Automatically Reconfigurable Computer

Modular system changes its architecture to maximize either reliability or capacity. Reconfigurable computer is assembled from four kinds of modules: organizer/scheduler, memory, input/output processor, and central processor. Reconfiguration is initiated by a signal from a control panel or by fault interrupt from one of the modules.

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NASA NTRS1986

An across-the-bay flight support structure designed specifically for the Spartan program

The preliminary design of an across-the-bay Flight Support Structure optimized to the specific requirements of the Spartan program has been completed. Although approximately 15 percent heavier than the initial goal, preliminary analysis indicate very low stress levels and significant reduction in weight should be possible in the final design. This structure is capable of supporting two Spartan 200-class spacecraft or attached payloads of equivalent total weight. The inherent structural efficiency of monocoque type construction is utilized. The minimization of fabrication and assembly costs and provision for simple and versatile payload interfacing where given significant considerations. Modularity of this structure allows it to be readily adapted for use as the primary structure of an Aries-class Spartan free-flyer utilizing the Orbit trunning latch mechanisms, thus eliminating the need for a flight support structure.

Rast, J. J.↗

NASA NTRS1993

New Mars vehicle concepts

The paper briefly reviews the evolution of the Mars vehicle design concepts from 1952 to 1990, and the currently understood requirements, constraints, and options for manned Mars missions in the early decades of the 21st century. The most up-to-date integrated Mars vehicle concepts for crew-carrying transfer and excursion vehicles are presented together with the Mars descent-ascent mission phases. Particular attention is given to a reusable transfer ship, which is a modular vehicle launched to earth orbit on six 185 t-class boosters and assembled there robotically; it uses dual nuclear-thermal rocket engines and liquid hydrogen propellant. The lander concept is capable of supporting many kinds of surface missions anywhere on Mars.

Sherwood, Brent↗

NASA NTRS2010

Modular Habitats Comprising Rigid and Inflatable Modules

Modular, lightweight, fully equipped buildings comprising hybrids of rigid and inflatable structures can be assembled on Earth and then transported to and deployed on the Moon for use as habitats. Modified versions of these buildings could also prove useful on Earth as shelters that can be rapidly and easily erected in emergency situations and/or extreme environments: examples include shelters for hurricane relief and for Antarctic exploration.

Kennedy, Kriss J.↗

NASA NTRS2005

How to Extend the Capabilities of Space Systems for Long Duration Space Exploration Systems

For sustainable Exploration Missions the need exists to assemble systems-of-systems in space, on the Moon or on other planetary surfaces. To fulfill this need new and innovative system architectures must be developed to be modularized and launched with the present lift capability of existing rocket technology. To enable long duration missions with minimal redundancy and mass, system software and hardware must be reconfigurable. This will enable increased functionality and multiple use of launched assets while providing the capability to quickly overcome components failures. Additional required capability includes the ability to dynamically demate and reassemble individual system elements during a mission in order to recover from failed hardware or to adapt to changes in mission requirements. To meet the Space Exploration goals of Interoperability and Reconfigurability, many challenges must be addressed to transform the traditional static avionics architectures into architectures with dynamic capabilities. The objective of this paper is to introduce concepts associated with reconfigurable computer systems; to review the various needs and challenges associated with reconfigurable avionics space systems; to provide an operational example that illustrates the application to both the Crew Exploration Vehicle and a collection of 'Habot-like' mobile surface elements; to summarize the approaches that address key challenges to the acceptance of a Flexible, Intelligent, Modular, Affordable and Reconfigurable avionics space system.

space assembly↗

NASA NTRS1994

Modular Cooling Components

Three modular heat-transfer components designed for use together or separately. Simple mechanical connections facilitate assembly of these and related heat-transfer components into cooling systems of various configurations, such as to cool laboratory equipment rearranged for different experiments. Components are clamp-on cold plate, cold plate attached to flexible heat pipe, and thermal-bus receptacle. Clamp-on cold plate moved to any convenient location for attachment of equipment cooled by it, then clamped onto thermal bus. Heat from equipment conducted through plate and into coolant. Thermal-bus receptacle integral with thermal bus. Includes part of thermal bus to which clamp-on cold plate attached, plus tapered socket into which condenser end of flexible heat pipe plugged. Thermal-bus receptacle includes heat-pipe wick structure using coolant in bus to enhance transfer of heat from cold plate.

Eastman, G. Yale↗

NASA NTRS1977

Improved fuel cell

Concept in fuel cell design has two cells, each with its own reactant flow fields bonded into single modular unit. Cells require fewer parts and occupy less space than conventional fuel cells, effecting easier assembly and maintenance.

Bell, W. F.↗