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At least 235 records · Page 13

The Role of Bearing and Scan Mechanism Life Testing in Flight Qualification of the MODIS Instrument

The Moderate Resolution Imaging Spectroradiometer (MODIS) is an instrument aboard the Terra (EOS AM-11) satellite and has been operating successfully since December 1999. MODIS has been viewing the entire Earth's surface and gathering data to better understand the global dynamics and processes occurring on land, in the oceans, and in the lower atmosphere. All observations are made through an extremely high resolution, optically and mechanically precise, scan mirror motor/encoder assembly. The reliable performance of this assembly depends on two duplex bearing pairs lubricated with Pennzane, a synthetic hydrocarbon, formulated with lead napthanate. This paper describes the results of accelerated and operational life tests. It also describes the post-test analyses of the disassembled bearings. Analyses were performed using micro-Raman, micro-FTIR, X-ray Photoelectron Spectroscopy (XPS), Scanning Electron Microscopy (SEM), and Size Exclusion Chromatography (SEC). In general, the three sets of bearings in each of the test stations were in very good condition after accumulating 68, 144, and 209 million revolutions, respectively. Some of the bearings exhibited lubricant degradation, indicated by viscous lubricant deposits on the cage and raceways.

VanDyk, Steven G.↗

MIR Solar Array Return Experiment: Power Performance Measurements and Molecular Contamination Analysis Results

A solar array segment was recently removed from the Mir core module and returned for ground-based analysis. The segment, which is similar to the ones the Russians have provided for the FGB and Service Modules, was microscopically examined and disassembled by US and Russian science teams. Laboratory analyses have shown the segment to he heavily contaminated by an organic silicone coating, which was converted to an organic silicate film by reactions with atomic oxygen within the. orbital flight environment. The source of the contaminant was a silicone polymer used by the Russians as an adhesive and bonding agent during segment construction. During its life cycle, the array experienced a reduction in power performance from approx. 12%, when it was new and first deployed, to approx. 5%, when it was taken out of service. However, current-voltage measurements of three contaminated cells and three pristine, Russian standard cells have shown that very little degradation in solar array performance was due to the silicate contaminants on the solar cell surfaces. The primary sources of performance degradation is attributed to "thermal hot-spotting" or electrical arcing; orbital debris and micrometeoroid impacts; and possibly to the degradation of the solar cells and interconnects caused by radiation damage from high energy protons and electrons.

Visentine, James↗

MC-1 LOX Pump Rotating Cavitation: Issue and Investigation

Leading edge tip deformation was noted on the LOX inducer from the component test unit at disassembly. The damage was in a location similar to a previous Fastrac water flow inducer failure. A team was formed to investigate the anomaly.

VanHooser, Katherine↗

The Role of Bearing and Scan Mechanism Life Testing in Flight Qualification of the MODIS Instrument

This paper describes the results of accelerated and operational life tests on bearings for the Moderate Resolution Imaging Spectroradiometer (MODIS). It also describes the post test analysis of the disassembled bearings. Analysis was performed using micro-Raman, micro-FTIR, X-ray Photoelectron Spectroscopy (XPS), Scanning Electron Microscopy (SEM), and Size Exclusion Chromatography (SEC). In general, the three sets of bearings in each of three test stations were in very good condition after accumulating 68, 144, and 209 million cycles, respectively. Some of the bearings exhibited lubricant degradation, indicated by viscous lubricant deposits on the cage and raceways.

VanDyk, Steven G.↗

The Role of Bearing and Scan Mechanism Life Testing in Flight Qualification of the MODIS Instrument

The Moderate Resolution Imaging Spectroradiometer (MODIS) is an instrument aboard the Terra (EOS AM-1) satellite and has been operating successfully since December 1999. MODIS has been viewing the entire Earth's surface and gathering data to better understand the global dynamics and processes occurring on land, in the oceans, and in the lower atmosphere. All observations are made through an extremely high resolution, optically and mechanically precise, scan mirror motor/encoder assembly. The reliable performance of this assembly depends on two duplex bearing pairs lubricated with Pennzane, a synthetic hydrocarbon, formulated with lead napthanate. This paper describes the results of accelerated and operational life tests. It also describes the post-test analyses of the disassembled bearings. Analyses were performed using micro-Raman, micro-FTIR, X-ray Photoelectron Spectroscopy (XPS), Scanning Electron Microscopy (SEM), and Size Exclusion Chromatography (SEC). In general, the three sets of bearings in each of the test stations were in very good condition after accumulating 68, 144, and 209 million revolutions, respectively. Some of the bearings exhibited lubricant degradation, indicated by viscous lubricant deposits on the cage and raceways.

VanDyk, Steven G.↗

Evaluation of Standard Gear Metrics in Helicopter Flight Operation

Each false alarm made by a machine monitoring system carries a high price tag. The machine must be taken out of service, thoroughly inspected with possible disassembly, and then made ready for service. Loss of use of the machine and the efforts to inspect it are costly. In addition, if a monitoring system is prone to false alarms, the system will soon be turned off or ignored. For aircraft applications, one growing concern is that the dynamic flight environment differs from the laboratory environment where fault detection methods are developed and tested. Vibration measurements made in flight are less stationary than those made in a laboratory, or test facility, and thus a given fault detection method may produce more false alarms in flight than might be anticipated. In 1977. Stewart introduced several metrics, including FM0 and FM4, for evaluating the health of a gear. These metrics are single valued functions of the vibration signal that indicate if the signal deviates from an ideal model of the signal. FM0 is a measure of the ratio of the peak-to-peak level to the harmonic energy in the signal. FM4 is the kurtosis of the signal with the gear mesh harmonics and first order side bands removed. The underlying theory is that a vibration signal from a gear in good condition is expected to be dominated by a periodic signal at the gear mesh frequency. If one or a small number of gear teeth contain damage or faults, the signal will change, possibly showing increased amplitude, local phase changes or both near the damaged region of the gear. FM0 increases if a signal contains a local increase in amplitude. FM4 increases if a signal contains a local increase in amplitude or local phase change in a periodic signal. Over the years, other single value metrics were also introduced to detect the onset and growth of damage in gears. These various metrics have detected faults in several gear tests in experimental test rigs. Conditions in these tests have been steady state in the sense that the rpm, torque and forces on the gear have been held steady. For gears used in a dynamic environment such as that occurring in aircraft, the rpm, torque and forces on the gear are constantly changing. The authors have measured significant variation in rpm and torque in the transmissions of helicopters in controlled steady flight conditions flown by highly proficient test pilots. Statistical analyses of the data taken in flight show significant nonstationarity in the vibration measurements. These deviations from stationarity may increase false alarms in gear monitoring during aircraft flight. In the proposed paper, the authors will study vibration measurements made in flight on an AH- 1 Cobra and an OH-58C Kiowa helicopters. The primary focus will be the development of a methodology to assess the impact of nonstationarity on false alarms. Issues to be addressed include how time synchronous averages are constructed from raw data as well as how lack of stationarity effects the behavior of single value metrics. Emphasis will be placed on the occurrence of false alarms with the use of standard metrics. In order to maintain an acceptable level of false alarms in the flight environment, this study will also address the determination of appropriate threshold levels, which may need to be higher than for test rigs.

Mosher, M.↗

Space Age Archaeology

In 1985, the Egyptian Antiques Organization (EAO) asked Dr. Farouk El-Baz whether it would be possible to examine and sample the second chamber of the subterranean chamber carved in the bedrock near the Great Pyramid of Khufu in Giza, Egypt, without admitting people, air or contaminants. He felt it could by applying space technology to the task. The initial contact led to a two year project which he organized and headed a team, co-sponsored by EAO and the National Geographic Society (NGS), to apply space technology in an effort to examine and photograph the Giza Chamber. The NGS photographic division modified and tested a remotely controlled video system and a 35-millimeter camera, and developed a lighting system that would not elevate the chamber temperature. Still needed was a drill to cut through the limestone cap without using lubricants or cooling fluids that might contaminate the chamber, and an airlock that would admit the drill shaft and photo equipment but not the air. Bob Moores from Black & Decker Corporation tailored a new drill to the Giza exploration. The drill bit broke through into the chamber at a depth of 63 inches, a stainless steel tube was lowered through the airlock to take samples of the chamber air at several levels. The video camera sent images from the chamber revealing that there was a disassembled royal boat that had been there.

Source record↗

Evolutionary Design of a Robotic Material Defect Detection System

During the post-flight inspection of SSME engines, several inaccessible regions must be disassembled to inspect for defects such as cracks, scratches, gouges, etc. An improvement to the inspection process would be the design and development of very small robots capable of penetrating these inaccessible regions and detecting the defects. The goal of this research was to utilize an evolutionary design approach for the robotic detection of these types of defects. A simulation and visualization tool was developed prior to receiving the hardware as a development test bed. A small, commercial off-the-shelf (COTS) robot was selected from several candidates as the proof of concept robot. The basic approach to detect the defects was to utilize Cadmium Sulfide (CdS) sensors to detect changes in contrast of an illuminated surface. A neural network, optimally designed utilizing a genetic algorithm, was employed to detect the presence of the defects (cracks). By utilization of the COTS robot and US sensors, the research successfully demonstrated that an evolutionarily designed neural network can detect the presence of surface defects.

Ballard, Gary↗

Assembly of Colloidal Materials Using Bioadhesive Interactions

We have pursued the use of biological crosslinking molecules of several types to make colloidal materials at relatively low volume fraction of colloidal particles. The objective is to make binary alloys of colloidal particles, made of two different colloidal particles coated with complementary biological lock-and-key binding molecules, which assemble due to the biological specificity. The long-term goal is to use low affinity lock-and-key biological interactions, so that the can anneal to form crystalline states. We have used a variety of different surface chemistries in order to make colloidal materials. Our first system involved using selectin-carbohydrate (sialyl-Lewis) interactions; this chemistry is derived from immune system. This chemical interaction is of relatively low affinity, with timescales for dissociation of several seconds. Furthermore, the adhesion mediated by these molecules can be reversed by the chelation of calcium atoms; thus assembled structures can be disassembled reversibly. Our second system employed avidin-biotin chemistry. This well-studied system is of high affinity, and is generally irreversible on a laboratory time-scale. Thus, we would expect selectin-carbohydrate interactions at high molecular density and avidin-biotin interactions to give kinetically-trapped structures; however, at low densities, we would expect significant differences in the structure and dynamics of the two materials, owing to their very different release rates. We have also begun to use a third chemistry - DNA hybridization. By attaching single stranded DNA oligonucleotide chains to beads, we can drive the assembly of colloidal materials by hybridization of complementary DNA chains. It is well known that DNA adenosine-thymine (A-T) and guanine-cytosine (G-C) bases hybridize pairwise with a Gibbs free energy change of 1.7 kcal/mol per base; thus, the energy of the assembly can be modulated by altering the number of complementary bases in the DNA chains. Using these different crosslinking molecules, we have assembled colloidal materials from different-sized colloidal particles, A and B. In the first sets of experiment, we used high densities of adhesion molecules, and 0.96 micron (A) and 5.5 micron (B) diameter particles. The high density of adhesion molecules means that the structures are kinetically trapped in nonequilibrium configurations. The structure of the suspension can be varied by changing the number ratio of the two types of colloidal particles, NA and NB, where A is the smaller particle. With carbohydrate-selectin or avidin-biotin interactions, large NA/NB leads to the formation of colloidal micelles, with the large center B particle surrounded by many smaller A particles. As the ratio NA/NB decreases, the structures become more extended, approaching the formation of macro-Rouse polymers - extended linear chains where A beads are connected with intervening small B linkers.

Hammer, Daniel A.↗

Development of a New Membrane Casting Apparatus for Studying Macrovoid Defects in Low-G

A new membrane-casting apparatus is developed for studying macrovoid defects in polymeric membranes made by the wet- and dry-casting process in low-gravity. Macrovoids are large (10-50 micron), open cavities interspersed among the smaller pores in the substructure under the gelled skin surface layer of the cast membrane. Although their occurrence is considered endemic to the wet- and dry-casting process since they can lead to compaction or skin rupture in the membrane process, recent studies suggest several useful applications such as transdermal and osmotic drug delivery systems, miniature bioreactors, etc. However, lack of knowledge about the macrovoid formation mechanism is an obstacle to further development of applications using them. An on-going debate is the role of the surface-tension-driven solutocapillary convection during macrovoid formation. The rapid growth of macrovoids within 1-5 seconds and the high polymer concentration in and near macrovoids make it difficult to explain the mechanism of macrovoid growth by diffusion alone, which is the widely accepted hypothesis proposed by Reuvers et al. The hypothesis advanced by our research group can explain this rapid growth via a mechanism that involves diffusion from the casting solution in the meta-stable region to the macrovoid enhanced by solutocapillary convection induced by the steep nonsolvent concentration gradient in the vicinity of the macrovoid. Since macrovoid growth is hypothesized to be the interplay of a solutocapillary-induced driving force counteracted by viscous drag and buoyancy, eliminate the latter provides a means for testing this hypothesis. Moreover, free convection mass transfer in the nonsolvent immersion bath used to cause phase-separation in membrane casting complicates developing a model for both the wet-casting process and macrovoid growth. The low-g environment minimizes gravitationally induced free convection thereby permitting a tractable solution to the ternary diffusion equations that characterize membrane formation. NASA's Parabolic Flight Research Aircraft provides a small window of low-g (approximately 25 s) that can be used to study macrovoid development in both wet- and dry-cast membranes if an appropriate casting apparatus is used. This casting apparatus should be able to cast the membrane in both low- and high-g in a manner so that essential one-dimensional mass transfer conditions are achieved to insure lateral uniformity in the membrane. The apparatus used in previous research on membrane casting in low-gravity was operated with the plunger driven mechanism. The spring-loaded plunger pushes the bottom block containing the polymer casting solution well directly under the absorbent chamber located in the upper stationary block. However, membranes made via this casting apparatus often displayed lateral nonuniformities that precluded obtaining quantitative information on the macrovoid growth process. Thus, it was necessary to determine the reason for these structural irregularities observed in the low-g casting apparatus. Both experimental as well as computer simulation studies of the low-g casting apparatus established that the impulsive action of the plunger caused the undesired structural nonuniformities. The simulation results showed that the width-to-depth aspect ratio of the shallow well that contains the casting solution in this apparatus was not an important factor in minimizing this problem. Even for a 40:1 (width : depth) aspect ratio, any convection induced by the horizontal motion of the interface of the casting solution will be damped out within 6.25x10(exp 4) seconds. However, the experimental studies revealed that the impulsive motion of the plunger caused a 'sloshing' of the casting solution that had to be eliminated. Therefore, the plungerdriven mechanism was changed to a cam-driven mechanism that did not cause any impulsive motion of the casting solution. Other refinements to this new membrane-casting apparatus include provision for removing the membranes from the casting wells in a less destructive manner. This was accomplished by using a slit geometry for the casting well that permitted disassembly for removal of the cast membrane. The materials used in the construction of this casting apparatus were chosen to insure wetting at the side walls and to maintain precise control of the thickness of the polymer solution in the casting well. An additional provision in this new casting apparatus is the ability to carry out both wet- as well as dry-casting. As such, this apparatus permitted the first studies of the wet-casting of polymeric membranes in low-g. Both wet- and dry-casting experiments on NASA's KC-135 research aircraft employing this new membrane-casting apparatus are scheduled in July 2002. The morphology of the resulting membranes will be characterized using an environmental scanning electron microscope (ESEM). The results of these low-g studies will be reported later.

Lee, Hanyong↗

Observational Investigation of Solar Interior and Atmosphere

The Imaging Vector Magnetograph (IVM) has been modified to make it easier to observe at more than one spectral line. The cell holding the blocking filter has been replaced by a four-position filter wheel, so that changing to a different line is a matter of a few minutes rather than the several hours it used to take to disassemble the cell and install a new filter. Three new filters have been obtained, for Na 1589.6 nm, Fe 1630.25 nm, and H 1656.3 nm. The new filters have better bandpass profiles than the ones they replaced: somewhat wider, with flatter tops and steeper wings. This results in a reduction of parasitic light coming from adjacent Fabry-Perot orders, from seven percent to about two percent, and flattens the apparent continuum. The Mees CCD Imaging Spectrograph (MCCD) was upgraded under this grant, with a new control computer and data system. The camera was replaced with a faster, larger-format frame-transfer camera. Final integration of the upgrades is not yet complete, but tests indicate that the system cadence will be improved by a factor of five to ten, while increasing the spatial coverage by a factor of two (depending on observation options). Synoptic observations with the IVM and MCCD continue to be conducted daily, to the extent permitted by the fact that we have a single observer responsible for the observations. The older Haleakala Stokes Polarimeter is also used to make a daily vector magnetogram, normally of the region selected by the Reuven Ramaty High Energy Solar Spectroscopic Imager (RHESSI) duty scientists. This instrument, however, is showing its age to the extent that its maintenance is becoming something of a challenge. We also run a white light full-disk imager and a video H alpha prominence camera, continuously during times of observations. Of particular interest, we obtained rapid-cadence observations of the 2003 July 15 white light flare with both the IVM and MCCD. The vector magnetograms show no obvious difference between the preflare and postflare configurations. The photospheric magnetogram sequence and H alpha spectra we obtained can be combined with spacecraft observations to construct a rather detailed picture of the events of this flare. Several papers are in preparation.

Kuhn, Jeffrey R.↗

RSRM Case Acceptance and Refurbishment Requirements

The RSRM (Reuseable Solid Rocket Motor) Program has been developed and implemented to support manned flight space travel. The Space Shuttle Vehicle utilizes two SRBs (Solid Rocket Boosters) to assist during the launch sequence and achieve the predefined orbit and mission objectives. A critical feature of this program involves post- flight SRB retrieval, disassembly and reuse of case structural components to manufacture future RSRM motors. To ensure these components can be safely reused, inspection criteria based on dimensional, structural and fracture requirements, has been established in the form of Engineering specifications and drawings. These criteria originated from actual hardware testing (both subscale and full scale) coupled with conventional Engineering hand calculations and computerized Finite Element Analyses (FEA). The intent of this paper is to provide an overview of the RSRM Case component refurbishment requirements and the associated case hardware inspection and evaluation processes that has been established to satisfy these requirements. Many of these processes have been recently upgraded to comply with environmental regulations, obsolescence concerns and technological advancements. Qualification of these process changes has been closely monitored and documented through test plans and reports.

Brinkerhoff, Gary Z.↗

Heat Treatment Devices and Method of Operation Thereof to Produce Dual Microstructure Superalloys Disks

A heat treatment assembly and heat treatment methods are disclosed for producing different microstructures in the bore and rim portions of nickel-based superalloy disks, particu- larly suited for gas turbine applications. The heat treatment assembly is capable of being removed from the furnace and disassembled to allow rapid fan or oil quenching of the disk. For solutioning heat treatments of the disk, temperatures higher than that of this solvus temperature of the disk are used to produce coarse grains in the rim of each disk so as to give maximum creep and dwell crack resistance at the rim service temperature. At the same time, solution temperature lower than the solvus temperature of the disk are provided to produce fine grain in the bore of the disk so as to give maximum strength and low cycle fatigue resistance.

John Gayda↗

Machine Vision Applied to Navigation of Confined Spaces

The reliability of space related assets has been emphasized after the second loss of a Space Shuttle. The intricate nature of the hardware being inspected often requires a complete disassembly to perform a thorough inspection which can be difficult as well as costly. Furthermore, it is imperative that the hardware under inspection not be altered in any other manner than that which is intended. In these cases the use of machine vision can allow for inspection with greater frequency using less intrusive methods. Such systems can provide feedback to guide, not only manually controlled instrumentation, but autonomous robotic platforms as well. This paper serves to detail a method using machine vision to provide such sensing capabilities in a compact package. A single camera is used in conjunction with a projected reference grid to ascertain precise distance measurements. The design of the sensor focuses on the use of conventional components in an unconventional manner with the goal of providing a solution for systems that do not require or cannot accommodate more complex vision systems.

Briscoe, Jeri M.↗

Hubble Space Telescope Fine Guidance Sensor Post-Flight Bearing Inspection

Aerospace mechanism engineering success stories often, if not always, consist of overcoming developmental, test and flight anomalies. Many times it is these anomalies that stimulate technology growth and more reliable future systems. However, one must learn from these to achieve an ultimately successful mission. It is not often that a spacecraft engineer is able to inspect hardware that has flown in orbit for several years. However, in February 1997, the Fine Guidance Sensor-I (FGS-1) was removed from the Hubble Space Telescope (HST) and returned to NASA Goddard Space Flight Center (GSFC) during the second Servicing Mission (SM2). At the time of removal, FGS-1 had nearly 7 years of service and the bearings in the Star Selector Servos (SSS) had accumulated approximately 25 million Coarse Track (CT) cycles. The main reason for its replacement was due to a bearing torque anomaly leading to stalling of the B Star Selector Servo (SSS-B) when reversing direction during a vehicle offset maneuver, referred to herein as a Reversal Bump (RB). The returned HST FGS SSS bearings were disassembled for post-service condition assessment to better understand the actual cause of the torque spikes, identify potential process/design improvements, and provide information for remedial on-orbit operation modifications. The methods and technology utilized for this inspection are not unique to this system and can be adapted to most investigation ai varying stages of the mechanism life from development, through testing, io post night evaluation. The systematic methods used for the HST Fine Guidance Sensor (FGS) SSS and specific findings are the subjects presented in this paper. The lessons learned include the importance of cleanliness and handling for precision instrument bearings and the potential effects from contamination. The paper describes in detail, the analytical techniques used for the SSS and their importance in this investigation. Inspection analytical data and photographs are included throughout the paper.

Pellicciotti, Joseph↗

Colossal Tooling Design: 3D Simulation for Ergonomic Analysis

The application of high-level 3D simulation software to the design phase of colossal mandrel tooling for composite aerospace fuel tanks was accomplished to discover and resolve safety and human engineering problems. The analyses were conducted to determine safety, ergonomic and human engineering aspects of the disassembly process of the fuel tank composite shell mandrel. Three-dimensional graphics high-level software, incorporating various ergonomic analysis algorithms, was utilized to determine if the process was within safety and health boundaries for the workers carrying out these tasks. In addition, the graphical software was extremely helpful in the identification of material handling equipment and devices for the mandrel tooling assembly/disassembly process.

Hunter, Steve L.↗

Hubble Space Telescope Fine Guidance Sensor Post-Flight Bearing Inspection

Aerospace mechanism engineering success stories often, if not always, consist of overcoming developmental, test and flight anomalies. Many times it is these anomalies that stimulate technology growth and more reliable future systems. However, one must learn from these to achieve an ultimately successful mission. It is not often that a spacecraft engineer is able to inspect hardware that has flown in orbit for several years. However, in February 1997, the Fine Guidance Sensor-1 (FGS-1) was removed from the Hubble Space Telescope (HST) and returned to NASA Goddard Space Flight Center (GSFC) during the second Servicing Mission (SM2). At the time of removal, FGS-1 had nearly 7 years of service and the bearings in the Star Selector Servos (SSS) had accumulated approximately 25 million Coarse Track (CT) cycles. The main reason for its replacement was due to a bearing torque anomaly leading to stalling of the B Star Selector Servo (SSS-B) when reversing direction during a vehicle offset maneuver, referred to herein as a Reversal Bump (RB). The returned HST FGS SSS bearings were disassembled for post-service condition assessment to better understand the actual cause of the torque spikes, identify potential process/design improvements, and provide information for remedial on-orbit operation modifications. The methods and technology utilized for this inspection are not unique to this system and can be adapted to most investigations at varying stages of the mechanism life from development, through testing, to post flight evaluation. The systematic methods used for the HST Fine Guidance Sensor (FGS) SSS and specific findings are the subjects presented in this paper. The lessons learned include the importance of cleanliness and handling for precision instrument bearings and the potential effects from contamination. The paper describes in detail, the analytical techniques used for the SSS and their importance in this investigation. Inspection analytical data and photographs are included throughout the paper.

Pellicciotti, J.↗

Robotic Assembly of Truss Structures for Space Systems and Future Research Plans

Many initiatives under study by both the space science and earth science communities require large space systems, i.e. with apertures greater than 15 m or dimensions greater than 20 m. This paper reviews the effort in NASA Langley Research Center's Automated Structural Assembly Laboratory which laid the foundations for robotic construction of these systems. In the Automated Structural Assembly Laboratory reliable autonomous assembly and disassembly of an 8 meter planar structure composed of 102 truss elements covered by 12 panels was demonstrated. The paper reviews the hardware and software design philosophy which led to reliable operation during weeks of near continuous testing. Special attention is given to highlight the features enhancing assembly reliability.

Doggett, William↗