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User manual for test equipment used in simulating aerodynamic heating and acoustical environments on space shuttle thermal protection specimens
The Advanced Integration Matrix (AIM) Project u7ill study and solve systems-level integration issues for exploration missions beyond Low Earth Orbit (LEO), through the design and development of a ground-based facility for developing revolutionary integrated systems for joint human-robotic missions. This paper describes a Probabilistic Risk Analysis (PRA) of human space missions that was developed to help define the direction and priorities for AIM. Risk analysis is required for all major NASA programs and has been used for shuttle, station, and Mars lander programs. It is a prescribed part of early planning and is necessary during concept definition, even before mission scenarios and system designs exist. PRA cm begin when little failure data are available, and be continually updated and refined as detail becomes available. PRA provides a basis for examining tradeoffs among safety, reliability, performance, and cost. The objective of AIM's PRA is to indicate how risk can be managed and future human space missions enabled by the AIM Project. Many critical events can cause injuries and fatalities to the crew without causing loss of vehicle or mission. Some critical systems are beyond AIM's scope, such as propulsion and guidance. Many failure-causing events can be mitigated by conducting operational tests in AIM, such as testing equipment and evaluating operational procedures, especially in the areas of communications and computers, autonomous operations, life support, thermal design, EVA and rover activities, physiological factors including habitation, medical equipment, and food, and multifunctional tools and repairable systems. AIM is well suited to test and demonstrate the habitat, life support, crew operations, and human interface. Because these account for significant crew, systems performance, and science risks, AIM will help reduce mission risk, and missions beyond LEO are far enough in the future that AIM can have significant impact.
Developed at NASA's Langley Research Center, the Macro-Fiber Composite (MFC) is designed to control vibration, noise, and deflections in composite structural beams and panels. Smart Material Corporation specializes in the development of piezocomposite components, and licensed the MFC technology from Langley in 2002. To date, Smart Material Corporation has sold MFCs to over 120 customers, including such industry giants as Volkswagen, Toyota, Honda, BMW, General Electric, and the tennis company, HEAD. The company estimates that its customers have filed at least 100 patents for their various unique uses of the technology. In addition, the company's product portfolio has grown to include piezoceramic fibers and fiber composites, piezoceramic actuators and sensors, and test equipment for these products. It also offers a compact, lightweight power system for MFC testing and validation. Consumer applications already on the market include piezoelectric systems as part of audio speakers, phonograph cartridges and microphones, and recreational products requiring vibration control, such as skis, snowboards, baseball bats, hockey sticks, and tennis racquets.
The Engineering and Technology Directorate (NE) at National Aeronautics and Space Administration (NASA) Kennedy Space Center (KSC) is designing a new command and control system for the checkout and launch of Space Launch System (SLS) and future rockets. The purposes of the semester long internship as a remote application software developer include the design, development, integration, and verification of the software and hardware in the firing rooms, in particular with the Mobile Launcher (ML) Launch Accessories (LACC) subsystem. In addition, a software test verification procedure document was created to verify and checkout LACC software for Launch Equipment Test Facility (LETF) testing.
The design, development, manufacture, test and calibration of five lunar orbital mass spectrometers with the four associated ground support equipment test sets are discussed. A mass spectrometer was installed in the Apollo 15 and one in the Apollo 16 Scientific Instrument Module within the Service Module. The Apollo 15 mass spectrometer was operated with collection of 38 hours of mass spectra data during lunar orbit and 50 hours of data were collected during transearth coast. The Apollo 16 mass spectrometer was operated with collection of 76 hours of mass spectra data during lunar orbit. However, the Apollo 16 mass spectrometer was ejected into lunar orbit upon malfunction of spacecraft boom system just prior to transearth insection and no transearth coast data was possible.
The development of a system of ultrasonic holography is discussed. The limitations of the acousto-optical transformers, the scanning method, and the Pohlman cell are analyzed. The application of the free liquid surface deformation method is emphasized. The test equipment required for the liquid surface deformation method is described. An illustration of a typical test installation is provided.
Articles are presented which are concerned with the development of special test equipment and a dual-frequency zero delay device (ZDD) that were required for range tests and the measurement of ground station delays for the Mariner-Venus-Mercury 1973 S/X-band experiment. Test data obtained at DSS 14 after installation of the ZDD on the 64-m antenna are given. It is shown that large variations of range were observed as a function of antenna elevation angle and were sensitive to antenna location. A ranging calibration configuration that was subsequently developed and a technique for determining the appropriate Z-correction are described. Zero delay test data at DSS 14 during the Mariner 10 Venus-Mercury-Encounter periods (1974 days 12-150) are presented. The theoretical analysis and experimental verifications are included of the effects of multipath and effects of discontinuities on range delay measurements. A movable subreflector technique and the multipath theory were used to isolate principal multipath errors on the 64-m antenna and to enable a more accurate determination of the actual ground station range delay.
This paper discusses the design configuration, performance and environmental capability of NASA's Dry Rotor Inertial Reference Unit (DRIRU II) for use in spacecraft precision attitude stabilization systems. The system is a self-contained, strapdown, dual rate sensing unit for spacecraft requiring high accuracy, reliability and low power consumption. Modular construction of the basic unit, arrangement of gyros, electronic modules and power supplies, signal flow, and mounting are described. DRIRU II is designed to meet specified performance requirements for a minimum of two years of operating time in orbit and a reliability prediction analysis is presented. The characteristics of test equipment are given together with the results of the environmental, radiation, and magnetic field sensitivity tests. DRIRU II may be modified for unique requirements and the rate range and resolution options are tabulated. The flexibility of the unit afforded by the use of dry tuned gimbal gyros and its modular construction results in a system capable of satisfying the demanding requirements of a broad spectrum of future applications. The units are planned for the Solar Max, Landsat-D and ASPS missions in the 1980's.
Sea level, static, ground testing of the over-the-wing engine and boilerplate nacelle components was performed. The equipment tested and the test facility are described. Summaries of the instrumentations, the chronological history of the tests, and the test results are presented.
A primary objective of the technical evaluation motor program is to recover the case, igniter and nozzle hardware for use on the redesigned solid rocket motor flight program. Two qualification objectives were addressed and met on TEM-3. The Nylok thread locking device of the 1U100269-03 leak check port plug and the 1U52295-04 safe and arm utilizing Krytox grease on the barrier-booster shaft O-rings were both certified. All inspection and instrumentation data indicate that the TEM-3 static test firing conducted 23 May 1989 was successful. The test was conducted at ambient conditions with the exception of the field joints (set point of 121 F, with a minimum of 87 F at the sensors), igniter joint (set point at 122 F with a minimum of 87 F at sensors) and case-to-nozzle joint (set point at 114 F with a minimum of 87 F at sensors). Ballistics performance values were within specification requirements. Nozzle performance was nominal with typical erosion. The nozzle and the case joint temperatures were maintained at the heaters controlling set points while electrical power was supplied. The water and the CO2 quench systems prevented damage to the metal hardware. All other test equipment performed as planned, contributing to a successful motor firing. All indications are that the test was a success, and all expected hardware will be refurbished for the RSRM program.
The Space Shuttle vehicle (SSV) is connected to the mobile launch platform (MLP) by four aft skirt hold down studs on each solid rocket booster (SRB). Prior to lift-off, the frangible nuts inside the aft skirt blast containers (BC) are severed into two nut halves by two pyrotechnic booster cartridges. This action releases the SSV and allows the hold down studs to eject through the aft skirt bore and then down into the MLP. USBI has been tasked to upgrade the BC for two specific reasons; 1. to eliminate lead for environmental concerns, and 2. to reduce the chance of nut recontact with the holddown stud. Nut recontact with the stud has been identified as a likely contributor to stud hangups. This upgrade will replace the lead liner with an aluminum foam material. The aluminum foam used as a energy absorber is a proven design in many other aerospace/defense applications. Additional benefits of using the open cell, energy absorbent aluminum foam in place of the solid lead liner are: A. Lead handling/ exposure, and possible contamination, along with hazardous waste disposal will be eliminated; B. Approximately 200 lbs. weight savings will be contributed to each Space Shuttle flight by using aluminum foam over lead; C. The new aluminum liner is designed to catch all shrapnel from frangible nuts thus virtually eliminating chance of foreign object debris (FOD) exiting the HDP, and causing potential damage to the vehicle; D. Potential of using the lighter aluminum liner over lead, allows for easier assembly and disassembly of blast container elements, also allowing for improvements in safety, operator handling, and efficiency of operations. Six BC firing tests will be required to determine if the new liner material will perform in a way to decrease the chance of stud hangups and enhance the ability of the BC to retain blast debris. Testing will be performed at the Kennedy Space Center (KSC) facility known as the Launch Equipment Test Facility (LETF), and will simulate the SRB hold- down post, with actual BC hardware and pyrotechnics assembled, and then test fired. Initial testing was performed in 1997 using a frangible nut in a static drop test over lead and aluminum foam sheet materials. The aluminum foam showed a dramatic improvement of energy absorption over the lead liner material. Proof-of-Principle testing at the KSC-LETF commenced in May, 1998, and is expected to be completed by June, 1998.
The launch operations test and checkout plan is a planning document that establishes all launch site checkout activity, including the individual tests and sequence of testing required to fulfill the development center and KSC test and checkout requirements. This volume contains the launch vehicle test and checkout plan encompassing S-1B, S-4B, IU stage, and ground support equipment tests. The plan is based upon AS-208 flow utilizing a manned spacecraft, LUT 1, and launch pad 39B facilities.
Programmable maintenance processor (MAINT) made of commercially available integrated circuits. Autonomous one of four digital electronic processors in extended aircraft interrogation and display system (XAIDS). Developed for testing of system and application computer programs as well as for testing equipment. MAINT has independent terminal and printer interfaces and dedicated magnetic bubble memory storing system-testing sequences entered from terminal. Software for MAINT written in PLM86 programming language and broken into four separate modules.
The SpaceHab 1 flight on STS-57 served as a test platform for evaluation of two space station payloads. The first payload evaluated a space station maintenance concept using a sweep signal generator and a 48-channel logic analyzer to perform fault detection and isolation. Crew procedures files, test setup diagram files, and software to configure the test equipment were created on the ground and uplinked on the astronauts' voice communication circuit to perform tests in flight. In order to use these files, the portable computer was operated in a multi-window configuration. The test data transmitted to the ground allowing the ground staff to identify the cause of the fault and provide the crew with the repair procedures and diagrams. The crew successfully repaired the system under test. The second payload investigated hand soldering and de-soldering of standard components on printed circuit (PC) boards in zero gravity. It also used a new type of intra-vehicular foot restraints which uses the neutral body posture in zero-g to provide retention of the crew without their conscious attention.
NOAA's three-axis stabilized series of GOES satellites have a place reserved on the Earth-facing side for an Instrument of Opportunity (IoO). The IoO slot is a location for new technologies that provide space-time-spectral resolution of the environment not possible with the preconceived Imager and Sounder. For example, candidate IoO's have usually proposed to use large-format staring arrays of detectors. The size, weight, power, data rate, and interface allocations for the IoO are modest in comparison to the Imager and Sounder, but the resources are large enough to allow for the collection of useful real time data. Because, the geosynchronous location is ideal for monitoring rapidly changing unpredictable events, IoO's have been suggested to detect lightning, volcanism, ozone and sulfur dioxide, ocean color, vegetation, special weather events, and even broadcast color TV. To become an IoO on GOES, the proposed instrument must: 1) have potential benefit to NOAA, 2) fit within the allocation constraints, 3) be independently funded, including pre-launch test equipment and the spacecraft accommodation costs, 4) be delivered two years before launch for integration and testing, and 5) not interfere with the existing launch schedule or the operational instruments.
Helicopter noise has consistently hindered operations within urban areas and surrounding communities. To combat this, an extensive flight test campaign, described herein, was conducted to gather acoustic data to support helicopter noise research (e.g., physics-based modeling, operational planning, etc.). Acoustic measurements were collected from four helicopters in the medium-sized weight class with maximum takeoff gross weights between 7,400 and 14,200 lb: a Bell 205 “Huey”, a Sikorsky S-76D, a Leonardo AW139, and a US Coast Guard MH-65 Dolphin (a variant of the commercial Airbus AS365 Dauphin). Each aircraft per- formed a subset of level flyovers, steady descents, turns with various initial conditions, and noise abatement approaches. A distributed ground microphone array spanning approximately 2,000 by 4,000 ft collected measurements of each flyover event. Additionally, a dedicated semicircular microphone array was used for gathering acoustic measurements of static conditions (e.g., hover). This report provides an overview of the flight test methodology, conditions tested, equipment used, and details of the accompanying distribution dataset. Figures of sample results generated for each test point are included to enable comparison and selection of the data at the discretion of the user. Specifically, source noise hemispheres of the steady flight conditions illustrate directivity of over- all levels. Noise contours over the array provide insight into the ground levels associated with approaches and turning events. These data figures are derived from the original acoustic pressure-time histories and vehicle tracking data that are provided in the distribution dataset.
A review of the scientific objectives of an integrated X-ray orbiting telescope facility is presented. A set of observations to be conducted to achieve the objectives of the research are described. The techniques and equipment used in the experiment are defined. The configuration of the facility and the specifications of the test equipment are included.
Laser Shearography is a viable inspection method for detection of de-bonds and voids within the external TPS (thermal protection system) on to the Space Shuttle RSRM (reusable solid rocket motors). Cork samples with thicknesses up to 1 inch were tested at the LTI (Laser Technology Incorporated) laboratory using vacuum-applied stress in a vacuum chamber. The testing proved that the technology could detect cork to steel un-bonds using vacuum stress techniques in the laboratory environment. The next logical step was to inspect the TPS on a RSRM. Although detailed post flight inspection has confirmed that ATK Thiokol's cork bonding technique provides a reliable cork to case bond, due to the Space Shuttle Columbia incident there is a great interest in verifying bond-lines on the external TPS. This interest provided and opportunity to inspect a RSRM motor with Laser Shearography. This paper will describe the laboratory testing and RSRM testing that has been performed to date. Descriptions of the test equipment setup and techniques for data collection and detailed results will be given. The data from the test show that Laser Shearography is an effective technology and readily adaptable to inspect a RSRM.