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The ET50 team was tasked with designing and analyzing various STE to support development and qualification tests for the Space Launch System (SLS) Payload Adapter Fitting (PAF). Axial, shear, and torsion load line assemblies are among the needed STE hardware. The product starts with a design concept with requirements by the customer.
The deep space and planetary exploration project have been acquiring more and more importance and some of them are now well established both in ESA and NASA programs. This paper presents the possibility to utilize both silicon and gallium arsenide solar cells as spacecraft primary power source for missions far from the Sun, in order to overcome the drawbacks related to the utilisation of radioisotope thermoelectric generators - such as cost, safety and social acceptance. The development of solar cells for low illumination intensity and low temperature (LILT) applications is carried out in Europe by ASE (Germany) and CISE (Italy) in the frame of an ESA programme, aimed to provide the photovoltaic generators for ROSETTA: the cometary material investigation mission scheduled for launch in 2003. The LILT cells development and testing objectives are therefore focused on the following requirements: insolation intensity as low as 0.03 Solar Constant, low temperature down to -150 C and solar flare proton environment. At this stage of development, after the completion of the technology verification tests, it has been demonstrated that suitable technologies are available for the qualification of both silicon and gallium arsenide cells and both candidates have shown conversion efficiencies over 25% at an illumination of 0.03 SC and a temperature of -150 C. In particular, when measured at those LILT conditions, the newly developed 'Hl-ETA/NR-LILT' silicon solar cells have reached a conversion efficiency of 26.3%, that is the highest value ever measured on a single junction solar cell. A large quantity of both 'Hl-ETA/NR-LILT' silicon and 'GaAs/Ge-LILT' solar cells are presently under fabrication and they will be submitted to a qualification test plan, including radiation exposure, in order to verify their applicability with respect to the mission requirements. The availability of two valid options will minimize the risk for the very ambitious scientific project. The paper describes how the technical achievements have been possible with Si and GaAs LILT solar cells (including a comparison between measured and modelled l-V characteristics) and it presents the technology verification tests results.
The development of a new launch vehicle to support NASA's future exploration plans requires significant redesign and upgrade of Kennedy Space Center's (KSC) launch pad and ground support equipment systems. In many cases, specialized test equipment and systems will be required to certify the function of the new system designs under simulated operational conditions, including propellant loading. This paper provides an overview of the cryogenic test infrastructure that is in place at KSC to conduct development and qualification testing that ranges from the component level to the integrated-system level. An overview of the major cryogenic test facilities will be provided, along with a detailed explanation of the technology focus area for each facility
The Six-degree-of-freedom Dynamic Test System (SDTS) is a short-range real-time motion based testing platform. Its primary use at NASA/JSC has been for development and qualification testing of docking systems, robotic assisted berthing mechanisms, and dynamic attachment systems. The SDTS is a closed-loop force feedback system that can simulate on-orbit contact dynamics between two vehicles utilizing the actual mechanical interfaces for testing. The facility is controlled by interconnected computers running real-time simulation software that takes measured contact forces, integrates the equations of motion in real time, and provide those states back into the motion table. This infrastructure can also be used for non-mating applications such as relative position sensor testing/evaluations. The SDTS facility provides a superstructure for mounting test articles, multiple test sensors, an intercom network for voice communications, and a synchronized timing system for data acquisition that includes HD video. This time-lapse video shows the buildup and testing of a modern electric actuation system created by Mikrolar, Inc. at the Johnson Space Center. This motion base will replace the current hydraulic actuator system, which is been in use since the 1970s, for all-future NASA testing. Once the system goes through customization to provide JSC’s unique closed-loop environment, the facility will help certify docking system and attach mechanisms on the ground before we send the first woman and the next man to the lunar surface
Published data on the processors sensitivites with respect to SEU is generally obtained from radiation ground testing during which the program is executed by the DUT consists in the sequential inspection of each of the processor memory cells accessible to the user, through the execution of a suitable instruction sequence. In such programs, so-called static tests, typically considered memory cells are general-purpose registers, special registers (program counter, stack pointer...) and internal memory. Nevertheless, the register use and duty cycle of the final application will be very different, including using instructions no in the static tests and disturbing other potential SEU targets. The ideal would be the use of the final application program for the radiation ground testing, but generally this program is either unknown or unavailable when the qualification testing is performed on candidate circuits to space projects.
These vibration, acoustic, and shock specifications provide the qualification test criteria for spacecraft components and subassemblies and for the High Energy Astronomy Observatory (HEAO-A) experiments. The HEAO-A was divided into zones and subzones to obtain simple component groupings. Zones are designated primarily to assist in determining the applicable specification. A Subzone is available for use when the location of the component is known but component design and weight are not well defined. When the location, weight, and mounting configuration of the component are known, the appropriate Subzone weight ranges are available. Experiment and specific component specifications are available.
The Certification of Propulsion Systems is costly and complex, involving development and qualification testing. The desire of the certification process is to assure all requirements can be demonstrated to be compliant. The purpose of this paper is to address the technical design concerns of certifying a propulsion system for flight. Presented are Pressurization, Tankage, Feed System and Combustion Instability concerns. Propulsion System Engineers are challenged with the dilemma for testing new systems to specific levels to reduce risk yet maintain budgetary targets. A methodical approach is presented to define the types of test suitable to address the technical issues for qualifying systems for retiring the risk levels. Experience of the lessons learned from supporting the Shuttle Program for Main Propulsion and On Orbit Propulsions Systems as well as previous collaborations on design concerns for certifying propulsion systems are utilized to address design concerns and verification approaches.
The key requirements, a design overview, development testing (qualification levels), and two problems and their solutions resolved during the mechanism development testing phase are presented. The mechanism described herein has demonstrated its capability to deploy/restow two large Hubble Space Telescope deployable appendages in a varying but controlled manner.
This document defines the test environment, test objectives, schedule, and data recording and analysis for the EOS/AMSU-A firmware formal qualification tests.
Payload and module integration development and qualification test plan for combined mission flights of Apollo applications program
The Certification of Propulsion Systems is costly and complex which involves development and qualification testing. The desire of the certification process is to assure all requirements can be demonstrated to be compliant. The purpose of this paper is to address the technical design concerns of certifying a system for flight. The authors of this paper have experience the lessons learned from supporting the Shuttle Program for Main Propulsion and On Orbit Propulsions Systems. They have collaborated design concerns for certifying propulsion systems. Presented are Pressurization, Tankage, Feed System and Combustion Instability concerns. Propulsion System Engineers are challenged with the dilemma for testing new systems to specific levels to reduce risk yet maintain budgetary targets. A methodical approach is presented to define the types of test suitable to address the technical issues for qualifying systems for retiring the risk levels.
This paper describes a rapid, top down requirements-driven design of an FPGA used in an Earth qualification test program for a new Mars subsonic parachute. The FPGA is used to process and store data from multiple sensors at multiple rates during launch, ascent, deployment and descent phases of the subsonic parachute test.
Acoustic testing of Apollo lunar module to determine structural and component integrity during launch
Spacecraft thermal control is accomplished for many components through use of multilayer insulation systems, electrical heaters, and radiator systems. The heaters are commanded to maintain component temperatures within design specifications. The programmable heater control circuit (PHCC) was designed to obtain an effective and efficient means of spacecraft thermal control. The hybrid circuit provides use of control instrumentation as temperature data, available to the spacecraft central data system, reprogramming capability of the local microprocessor during the spacecraft's mission, and the elimination of significant spacecraft wiring. The hybrid integrated circuit has a temperature sensing and conditioning circuit, a microprocessor, and a heater power and control circuit. The device is miniature and housed in a volume which allows physical integration with the component to be controlled. Applications might include alternate battery-powered logic-circuit configurations. A prototype unit with appropriate physical and functional interfaces was procured for testing. The physical functionality and the feasibility of fabrication of the hybrid integrated circuit were successfully verified. The remaining work to develop a flight-qualified device includes fabrication and testing of a Mil-certified part. An option for completing the PHCC flight qualification testing is to enter into a joint venture with industry.
As deep space exploration continues to be the goal of NASAs human spaceflight program, verification of the performance of spaceflight hardware becomes increasingly critical. Suitable test methods for verifying the leak rate of sealing systems are identified in program qualification testing requirements. One acceptable method for verifying the air leak rate of gas pressure seals is the tracer gas leak detector method. In this method, a tracer gas (commonly helium) leaks past the test seal and is transported to the leak detector where the leak rate is quantified. To predict the air leak rate, a conversion factor of helium-to-air is applied depending on the magnitude of the helium flow rate. The conversion factor is based on either the molecular mass ratio or the ratio of the dynamic viscosities. The current work was aimed at validating this approach for permeation-level leak rates using a series of tests with a silicone elastomer O-ring. An established pressure decay method with constant differential pressure was used to evaluate both the air and helium leak rates of the O-ring under similar temperature and pressure conditions. The results from the pressure decay tests showed, for the elastomer O-ring, that neither the molecular flow nor the viscous flow helium-to-air conversion factors were applicable. Leak rate tests were also performed using nitrogen and argon as the test gas. Molecular mass and viscosity based helium-to-test gas conversion factors were applied, but did not correctly predict the measured leak rates of either gas. To further this study, the effect of pressure boundary conditions was investigated. Often, pressure decay leak rate tests are performed at a differential pressure of 101.3 kPa with atmospheric pressure on the downstream side of the test seal. In space applications, the differential pressure is similar, but with vacuum as the downstream pressure. The same O-ring was tested at four unique differential pressures ranging from 34.5 to 137.9 kPa. Up to six combinations of upstream and downstream pressures for each differential pressure were compared. For a given differential pressure, the various combinations of upstream and downstream dry air pressures did not significantly affect the leak rate. As expected, the leak rate of the O-ring increased with increasing differential pressure. The results suggested that the current leak test pressure conditions, used to verify spacecraft sealing systems with elastomer seals, produce accurate values even though the boundary conditions do not model the space application.
An Engineering-of-Failure approach to designing and executing an accelerated product qualification test was performed to support a risk assessment of a "work-around" necessitated by an on-orbit failure of another piece of hardware on the Mars Global Surveyor spacecraft. The proposed work-around involved exceeding the previous qualification experience both in terms of extreme cold exposure level and in terms of demonstrated low cycle fatigue life for the power shunt assemblies. An analysis was performed to identify potential failure sites, modes and associated failure mechanisms consistent with the new use conditions. A test was then designed and executed which accelerated the failure mechanisms identified by analysis. Verification of the resulting failure mechanism concluded the effort.
Sampling output levels of accelerometers using largest output or any combination of outputs provide control of shaker for spacecraft vibration qualification tests.
The Gemini, Apollo and Space Shuttle spacecraft utilized explosive transfer lines (ETL) in a number of applications. In each case the ETL was located behind substantial structure and the risk of impact initiation by micrometeoroids and orbital debris was negligible. A current NASA program is considering an ETL to synchronize the actuation of pyrobolts to release 12 capture latches in a contingency. The space constraints require placing the ETL 50 mm below the 1 mm thick 2024-T72 Whipple shield. The proximity of the ETL to the thin shield prompted analysts at NASA to perform a scoping analysis with a finite-difference hydrocode to calculate impact parameters that would initiate the ETL. The results suggest testing is required and a 12 shot test program with surplused Shuttle ETL is scheduled for February 2012 at the NASA White Sands Test Facility. Explosive initiation models are essential to the analysis and one exists in the CTH library for HNS I, but not the HNS II used in the Shuttle 2.5 gr/ft rigid shielded mild detonating cord (SMDC). HNS II is less sensitive than HNS I so it is anticipated that these results using the HNS I model are conservative. Until the hypervelocity impact test results are available, the only check on the analysis was comparison with the Shuttle qualification test result that a 22 long bullet would not initiate the SMDC. This result was reproduced by the hydrocode simulation. Simulations of the direct impact of a 7 km/s aluminum ball, impacting at 0 degree angle of incidence, onto the SMDC resulted in a 1.5 mm diameter ball initiating the SMDC and 1.0 mm ball failing to initiate it. Where one 1.0 mm ball could not initiate the SMDC, a cluster of six 1.0 mm diameter aluminum balls striking simultaneously could. Thus the impact parameters that will result in initiating SMDC located behind a Whipple shield will depend on how well the shield fragments the projectile and spreads the fragments. An end-to-end simulation of the impact of an aluminum ball onto a Whipple shield covering SMDC is problematic due to the hydrocode fracture models. Regardless, two simulations were performed resulting in a 5 mm ball initiating the SMDC and a 4 mm ball failing to initiate the SMDC.