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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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NASA NTRS1979

High performance N2O4/amine elements blowapart

Hypergolic earth-storable N2O4/Amine propellants are used for a wide range of liquid propulsion system applications. These propellants are highly reactive and can experience reactive stream separation (RSS, i.e., blowapart) which can inhibit intraelement mixing, hence reducing the overall spray mixture ratio and mass distribution, which can result in altered combustion efficiency, gas-side heat transfer coefficient, and stability. An experimental and analytical program was conducted to develop an understanding of the mechanisms controlling RSS. The program and product was development of design criteria for coping with RSS to allow the design of high performing, stable injectors. RSS mechanisms were identified using high speed color photography to observe reactive stream mixing of single element injectors tested with N2O4/MMH, N2O4/A-50, and N2O4/N2H4 propellants. The parametric characterization included modeling of the Space Shuttle Orbital Maneuvering System and Reaction Control System engine injectors.

Source record↗
NASA NTRS2016

Large Payload Ground Transportation and Test Considerations

During test and verification planning for the Altair lunar lander project, a National Aeronautics and Space Administration (NASA) study team identified several ground transportation and test issues related to the large payload diameter. Although the entire Constellation Program-including Altair-has since been canceled, issues identified by the Altair project serve as important lessons learned for payloads greater than 7 m diameter being considered for NASA's new Space Launch System (SLS). A transportation feasibility study found that Altair's 8.97 m diameter Descent Module would not fit inside available aircraft. Although the Ascent Module cabin was only 2.35 m diameter, the long reaction control system booms extended nearly to the Descent Module diameter, making it equally unsuitable for air transportation without removing the booms and invalidating assembly workmanship screens or acceptance testing that had already been performed. Ground transportation of very large payloads over extended distances is not generally permitted by most states, so overland transportation alone would not be an option. Limited ground transportation to the nearest waterway may be possible, but water transportation could take as long as 66 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA's Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing such as hypergolic fuels, pyrotechnic devices, and high pressure gasses. Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure-roads, bridges, airframes, and buildings-necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider where and how large spacecraft are manufactured, tested, and launched could result in unforeseen cost to modify existing (or develop new) infrastructure, or incur additional risk due to increased handling operations or eliminating key verifications.

Rucker, Michelle A.↗
NASA NTRSDate not supplied

Integrated Design Results for the MSR DAC-0.0 Mars Ascent Vehicle

The NASA Mars Sample Return (MSR) Campaign endeavors to return Martian regolith, rock, and atmospheric samples to Earth for scientific study. One of many significant challenges to overcome in the return of these samples lies in transporting them from the Martian surface to space. In order to surmount this challenge, the Campaign has conceptualized the need for a Mars Ascent Vehicle (MAV) to perform this function and deliver Martian samples to orbit. There, the samples will be ejected and captured by a separate spacecraft for return to Earth. Many concepts for a MAV have existed in the past, but it has not been until now that an integrated, detailed design solution has been developed and analyzed. Preliminary assessments of the initial architecture examined multiple methods of propulsion. The team ultimately determined that a Two Stage to Orbit (TSTO) solid propulsion vehicle would provide the most effective performance and be the most technologically ready to support this mission. Following the decision to adopt a TSTO solid propelled vehicle, the first official Design Analysis Cycle, DAC-0.0, was performed in Spring 2020 to formally advance the fidelity of the vehicle to a maturity level acceptable for NASA Key Decision Point A (KDP-A). This paper describes the resultant MAV design concept developed as part of the DAC-0.0 study by the NASA Marshall Space Flight Center (MSFC), in association with the NASA Jet Propulsion Laboratory (JPL). The TSTO vehicle features two solid rocket motors, one powering each stage. Their thrust vectors are controlled with Thrust Vector Control (TVC) systems consisting of independent electromechanical actuators acting on gimballed nozzles. The vehicle is designed to deliver up to 0.47kg of Martian samples to a Mars circular orbit of 343km at 27° inclination. Due to the unique environmental conditions that this vehicle is required to operate in, the subsystem design teams were compelled to develop creative and unorthodox designs to ensure a successful mission. The detailed design and analysis of these subsystems are discussed in this paper and include topics on the MAV Guidance, Navigation, and Control (GNC); structures and mechanisms; integrated vehicle thermal; avionics and flight software; a hydrazine-based Reaction Control System (RCS); aerosciences; and vehicle assembly, integration, and test (AI&T) considerations, among others. Following the conclusion of the MAV DAC-0.0, additional alternative architecture concepts were also studied to further reduce the mass of the overall system. The results of these studies will also be examined in this paper.

Darius Yaghoubi↗
NASA NTRSDate not supplied

Integrated Design Results for the MSR DAC-0.0 Mars Ascent Vehicle

The NASA Mars Sample Return (MSR) Campaign endeavors to return Martian regolith, rock, and atmospheric samples to Earth for scientific study. One of many significant challenges to overcome in the return of thesesamples lies in transporting them from the Martian surface to space. In order to surmount this challenge, the Campaign has conceptualized the need for a Mars Ascent Vehicle (MAV) to perform this function and deliver Martian samples to orbit. There, the samples will be ejected and captured by a separate spacecraft for return to Earth. Many concepts for a MAV have existed in the past, but it has not been until now that an integrated, detailed design solution has been developed and analyzed. Preliminary assessments of the initial architecture examined multiple methods of propulsion. The team ultimately determined that a Two Stage to Orbit (TSTO) solid propulsion vehicle would provide the most effective performance and be the most technologically ready to support this mission. Following the decision to adopt a TSTO solid propelled vehicle, the first official Design Analysis Cycle, DAC-0.0, was performed in Spring 2020 to formally advance the fidelity of the vehicle to a maturity level acceptable for NASA Key Decision Point A (KDP-A). This paper describes the resultant MAV design concept developed as part of the DAC-0.0 study by the NASA Marshall Space Flight Center (MSFC), in association with the NASA Jet Propulsion Laboratory (JPL). The TSTO vehicle features two solid rocket motors, one powering each stage. Their thrust vectors are controlled with Thrust Vector Control (TVC) systems consisting of independent electromechanical actuators acting on gimballed nozzles. The vehicle is designed to deliver up to 0.47kg of Martian samples to a Mars circular orbit of 343km at 27° inclination. Due to the unique environmental conditions that this vehicle is required to operate in, the subsystem design teams were compelled to develop creative and unorthodox designs to ensure a successful mission. The detailed design and analysis of these subsystems are discussed in this paper and include topics on the MAV Guidance, Navigation, and Control (GNC); structures and mechanisms; integrated vehicle thermal; avionics and flight software; a hydrazine-based Reaction Control System (RCS); aerosciences; and vehicle assembly, integration, and test (AI&T) considerations, among others. Following the conclusion of the MAV DAC-0.0, additional alternative architecture concepts were also studied to further reduce the mass of the overall system.

Mars↗
NASA NTRS2024

Considerations for Thrust Vector Control (TVC) In-Flight Load Predictions

This presentation communicates an overview of a methodology developed by the National Aeronautics and Space Administration (NASA) Marshall Space Flight Center (MSFC) Thrust Vector Control (TVC) Systems Integration & Components Branch (MSFC-ER63). The methodology is based on NASA heritage TVC design practices and is designed to analyze the summation of static and quasi-static environments acting on a gimbaled rocket engine/motor system. The analysis determines the maximum overall expected induced torque acting on the rocket engine/motor system about the gimbal center of rotation and assumes a mathematical 3-Dimensional (3D) 2-Degree-of-Freedom (DOF) rigid-body pendulum model over a predefined range of angular motion. Additionally, it calculates the associated reaction force acting along a TVC actuator line-of-action (LOA) to maintain thrust vector holding operations. This methodology is particularly useful for determining maximum overall design loads for TVC actuator design-space shaping and requirements determination.

Thrust Vector Control↗
NASA NTRS2010

Challenges to Computational Aerothermodynamic Simulation and Validation for Planetary Entry Vehicle Analysis

Challenges to computational aerothermodynamic (CA) simulation and validation of hypersonic flow over planetary entry vehicles are discussed. Entry, descent, and landing (EDL) of high mass to Mars is a significant driver of new simulation requirements. These requirements include simulation of large deployable, flexible structures and interactions with reaction control system (RCS) and retro-thruster jets. Simulation of radiation and ablation coupled to the flow solver continues to be a high priority for planetary entry analyses, especially for return to Earth and outer planet missions. Three research areas addressing these challenges are emphasized. The first addresses the need to obtain accurate heating on unstructured tetrahedral grid systems to take advantage of flexibility in grid generation and grid adaptation. A multi-dimensional inviscid flux reconstruction algorithm is defined that is oriented with local flow topology as opposed to grid. The second addresses coupling of radiation and ablation to the hypersonic flow solver - flight- and ground-based data are used to provide limited validation of these multi-physics simulations. The third addresses the challenges of retro-propulsion simulation and the criticality of grid adaptation in this application. The evolution of CA to become a tool for innovation of EDL systems requires a successful resolution of these challenges.

Gnoffo, Peter A.↗
NASA NTRS2010

Challenges to Computational Aerothermodynamic Simulation and Validation for Planetary Entry Vehicle Analysis

Challenges to computational aerothermodynamic (CA) simulation and validation of hypersonic flow over planetary entry vehicles are discussed. Entry, descent, and landing (EDL) of high mass to Mars is a significant driver of new simulation requirements. These requirements include simulation of large deployable, flexible structures and interactions with reaction control system (RCS) and retro-thruster jets. Simulation of radiation and ablation coupled to the flow solver continues to be a high priority for planetary entry analyses, especially for return to Earth and outer planet missions. Three research areas addressing these challenges are emphasized. The first addresses the need to obtain accurate heating on unstructured tetrahedral grid systems to take advantage of flexibility in grid generation and grid adaptation. A multi-dimensional inviscid flux reconstruction algorithm is defined that is oriented with local flow topology as opposed to grid. The second addresses coupling of radiation and ablation to the hypersonic flow solver--flight- and ground-based data are used to provide limited validation of these multi-physics simulations. The third addresses the challenges of retro-propulsion simulation and the criticality of grid adaptation in this application. The evolution of CA to become a tool for innovation of EDL systems requires a successful resolution of these challenges.

Gnoffo, Peter A.↗
DOE OSTI2022

Automated Control for Nuclear Thermal Propulsion Start-Up using MOOSE-based Applications

This report presents a Griffin/Bison/RELAP-7 numerical model of a prototypical NTP system that features fuel assemblies arranged in rings, and which was designed to simulate rapid startup transients. The physics modeled include full-core neutronics, assembly-wise heat conduction, and conjugate heat transfer, with the balance of plant mainly imposed through boundary conditions. In addition, various forms of automated reactivity control were deployed by using the MOOSE to autonomously drive the model and simulate the reactor transitioning from assumed initial conditions to nominal power in a fraction of a minute. To generate the cross-sections of the neutronics model, and in an effort to simultaneously account for the tremendous axial temperature gradients in the reactor and to limit the number of state points required for cross-section generation, the average component temperatures and hydrogen densities in the cooling channels were correlated to the average fuel and moderator temperatures, and fixed axial profiles were derived for nominal conditions and then used during the transient. With this approximation, a tractable cross-section library tabulated with fuel/moderator temperatures and CD angles was generated using Serpent. The full-core SPH correction procedure and the CD decusping technology in Griffin, respectively, ensure preservation of the multiplication factor and reaction rates at state points, along with a reasonably accurate reactivity worth between tabulated CD angles, despite using a coarse mesh. Feedback from other physics was calculated by modeling one representative fuel assembly per ring, along with the corresponding fuel and moderator cooling channels. To limit power overshoots during startup, another layer of multiphysics coupling was added to the model in order to automatically control the drums. Two different technologies presented herein showed outstanding performance in this regard: (1) a novel hybrid PID controller based on both power and reactivity signals, and (2) a PGC that relies on kinetics parameters and reactivity coefficients to predict future behavior and adjust the desired signal accordingly. A challenging benchmark was devised, featuring a power demand curve that exponentially increases by a factor of 500 within 30 seconds, then levels out after that. Both control approaches create a simulated power curve that closely follows the power demand curve and limits power overshoots to 1% or less. While the former approach requires more tuning of the internal parameters, the latter requires additional knowledge of the reactivity feedback coefficients and rates of change of the corresponding variables, including fuel and moderator temperature, which could be difficult to dynamically measure for a real NTP system. Fortunately, some inaccuracy in these quantities will not drastically degrade the PGC performance. Subsequently, a more realistic startup sequence was considered, in which the mass flow rate and outlet pressures are ramped up to model bootstrap and thrust build-up phases prior to reaching steady-state conditions, demonstrating the ability of the hybrid PID and PGCs to handle such transients, with both types of controllers exhibiting very similar behavior. Nevertheless, a significant chamber temperature overshoot was observed, caused by the demanded power signal and assumed mass flow rate. This issue could be mitigated by deploying a reactor controller that follows the chamber temperature signal and actuates both the control valves and drums (rather than using a power signal based solely on the drums to control reactivity). Enhancement of the hydrogen fluid properties available in MOOSE, as well as a better understanding of prototypical initial conditions, are also needed to further enhance this startup model. Finally, a study was performed to model decay heat post-shutdown, and to prepare for extending this model to predict shutdown behavior and post-shutdown pulsed cooling requirements.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1972

Mercury contamination study for flight system safety

The effects and prevention of possible mercury pollution from the failure of solar electric propulsion spacecraft using mercury propellant were studied from tankage loading of post launch trajector injection. During preflight operations and initial flight mode there is little danger of mercury pollution if proper safety precautions are taken. Any spillage on the loading, mating, transportation, or launch pad areas is obvious and can be removed by vacuum cleaning soil and chemical fixing. Mercury spilled on Cape Kennedy ground soil will be chemically complexed and retained by the sandstone subsoil. A cover layer of sand or gravel on spilled mercury which has settled to the bottom of a water body adjacent to the system operation will control and eliminate the formation of toxic organic mercurials. Mercury released into the earth's atmosphere through leakage of a fireball will be diffused to low concentration levels. However, gas phase reactions of mercury with ozone could cause a local ozone depletion and result in serious ecological hazards.

Gorzynski, C. S., Jr.↗
DOE OSTI2022

NO x Control and Measurement Technology for Heavy-Duty Diesel Engines (CRADA Final Report)

The Catalyst CRADA focused on lean-NO x trap (LNT) and selective catalytic reduction (SCR) automotive emission control catalyst technology. It particularly had the goal of developing and applying advanced diagnostics capable of elucidating the network and sequence of catalyst reactions, as well as how they are affected by real-world operation and aging. Another overarching goal and action of this CRADA section was to develop methods to quantify and monitor catalyst states and support the development of full and reduced models for design and in-use control applications. William Partridge was the ORNL principal investigator (PI) throughout the Catalyst CRADA; Neal Currier was the Cummins PI through circa 2017, and Saurabh Joshi was the subsequent Cummins PI.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS1992

Thermostructural responses of carbon phenolics in a restrained thermal growth test

The thermostructural response of carbon phenolic components in a solid rocket motor (SRM) is a complex process. It involves simultaneous heat and mass transfer along with chemical reactions in a multiphase system with time-dependent material properties and boundary conditions. In contrast to metals, the fracture of fiber-reinforced composites is characterized by the initiation and progression of multiple failures of different modes such as matrix cracks, interfacial debonding, fiber breaks, and delamination. The investigation of thermostructural responses of SRM carbon phenolics is further complicated by different failure modes under static and dynamic load applications. Historically, there have been several types of post-firing anomalies found in the carbon phenolic composites of the Space Shuttle SRM nozzle. Three major failure modes which have been observed on SRM nozzles are pocketing (spallation), ply-lift, and wedge-out. In order to efficiently control these anomalous phenomena, an investigation of fracture mechanisms under NASA/MSFC RSRM (Redesigned Solid Rocket Motor) and SPIP (Solid Propulsion Integrity Program) programs have been conducted following each anomaly. This report reviews the current progress in understanding the effects of the thermostructural behavior of carbon phenolics on the failure mechanisms of the SRM nozzle. A literature search was conducted and a technical bibliography was developed to support consolidation and assimilation of learning from the RSRM and SPIP investigation efforts. Another important objective of this report is to present a knowledge-based design basis for carbon phenolics that combines the analyses of thermochemical decomposition, pore pressure stresses, and thermostructural properties. Possible areas of application of the knowledge-based design include critical material properties development, nozzle component design, and SRM materials control.

Wang, C. Jeff↗
NASA NTRS2003

Catalyzed Combustion of Bipropellants for Micro-Spacecraft Propulsion

This paper addresses the need to understand the physics and chemistry involved in propellant combustion processes in micro-scale combustors for propulsion systems on micro-spacecraft. These spacecraft are planned to have a mass less than 50 kilograms with attitude control estimated to be in the 10 milli-Newton thrust class. These combustors are anticipated to be manufactured using Micro Electrical Mechanical Systems (MEMS) technology and are expected to have diameters approaching the quenching diameter of the propellants. Combustors of this size are expected to benefit significantly from surface catalysis processes. Miniature flame tube apparatus is chosen for this study because microtubes can be easily fabricated from known catalyst materials and their simplicity in geometry can be used in fundamental simulations for validation purposes. Experimentally, we investigated the role of catalytically active surfaces within 0.4 and 0.8 mm internal diameter microtubes, with special emphases on ignition processes in fuel rich gaseous hydrogen and gaseous oxygen. Flame thickness and reaction zone thickness calculations predict that the diameters of our test apparatus are below the quenching diameter of the propellants in sub-atmospheric tests. Temperature and pressure rise in resistively heated platinum and palladium microtubes was used as an indication of exothermic reactions. Specific data on mass flow versus preheat temperature required to achieve ignition are presented. With a plug flow model, the experimental conditions were simulated with detailed gas-phase chemistry, thermodynamic properties, and surface kinetics. Computational results generally support the experimental findings, but suggest an experimental mapping of the exit temperature and composition is needed.

Schneider, Steven J.↗
NASA NTRS2013

Orion MPCV GN and C End-to-End Phasing Tests

End-to-end integration tests are critical risk reduction efforts for any complex vehicle. Phasing tests are an end-to-end integrated test that validates system directional phasing (polarity) from sensor measurement through software algorithms to end effector response. Phasing tests are typically performed on a fully integrated and assembled flight vehicle where sensors are stimulated by moving the vehicle and the effectors are observed for proper polarity. Orion Multi-Purpose Crew Vehicle (MPCV) Pad Abort 1 (PA-1) Phasing Test was conducted from inertial measurement to Launch Abort System (LAS). Orion Exploration Flight Test 1 (EFT-1) has two end-to-end phasing tests planned. The first test from inertial measurement to Crew Module (CM) reaction control system thrusters uses navigation and flight control system software algorithms to process commands. The second test from inertial measurement to CM S-Band Phased Array Antenna (PAA) uses navigation and communication system software algorithms to process commands. Future Orion flights include Ascent Abort Flight Test 2 (AA-2) and Exploration Mission 1 (EM-1). These flights will include additional or updated sensors, software algorithms and effectors. This paper will explore the implementation of end-to-end phasing tests on a flight vehicle which has many constraints, trade-offs and compromises. Orion PA-1 Phasing Test was conducted at White Sands Missile Range (WSMR) from March 4-6, 2010. This test decreased the risk of mission failure by demonstrating proper flight control system polarity. Demonstration was achieved by stimulating the primary navigation sensor, processing sensor data to commands and viewing propulsion response. PA-1 primary navigation sensor was a Space Integrated Inertial Navigation System (INS) and Global Positioning System (GPS) (SIGI) which has onboard processing, INS (3 accelerometers and 3 rate gyros) and no GPS receiver. SIGI data was processed by GN&C software into thrust magnitude and direction commands. The processing changes through three phases of powered flight: pitchover, downrange and reorientation. The primary inputs to GN&C are attitude position, attitude rates, angle of attack (AOA) and angle of sideslip (AOS). Pitch and yaw attitude and attitude rate responses were verified by using a flight spare SIGI mounted to a 2-axis rate table. AOA and AOS responses were verified by using a data recorded from SIGI movements on a robotic arm located at NASA Johnson Space Center. The data was consolidated and used in an open-loop data input to the SIGI. Propulsion was the Launch Abort System (LAS) Attitude Control Motor (ACM) which consisted of a solid motor with 8 nozzles. Each nozzle has active thrust control by varying throat area with a pintle. LAS ACM pintles are observable through optically transparent nozzle covers. SIGI movements on robot arm, SIGI rate table movements and LAS ACM pintle responses were video recorded as test artifacts for analysis and evaluation. The PA-1 Phasing Test design was determined based on test performance requirements, operational restrictions and EGSE capabilities. This development progressed during different stages. For convenience these development stages are initial, working group, tiger team, Engineering Review Team (ERT) and final.

Neumann, Brian C.↗
NASA NTRS2017

Narrowband Rejection of Reaction Wheel and Environmental Disturbances for the WFIRST OMC Testbed

The Wide Field Infrared Survey Telescope (WFIRST) is a NASA observatory with two scientific instruments. The first is the Wide Field Instrument (WFI) designed to perform wide field imaging and surveys of the near infrared (NIR) sky. The second is a coronagraph (CGI) that will enable astronomers to detect and measure properties of planets in other solar systems. The coronagraph requires 0.5 milli-arcsecond (mas) RMS pointing per axis of the line of sight (LOS) to achieve a contrast of 1x10-9. This paper discusses the approach used for achieving this level of pointing performance on the occulting mask coronagraph (OMC) testbed at JPL. This testbed uses a low-order wavefront sensing (LOWFS) camera and fast steering mirror (FSM) to suppress injected LOS jitter and environmental LOS jitter. The injected jitter includes representative broadband spacecraft attitude control system (ACS) LOS motion and tonal LOS jitter caused by the reaction wheel assemblies (RWA). The environmental jitter includes thermal LOS variations and harmonics of the line noise. The LOWFS camera uses high flux from the obscured science target to achieve high rate measurements of the LOS. These measurements are augmented with fictitious RWA tachometer information and an estimate of the line noise frequency. A LOS servo using a combination of feedback and feedforward control is used in the testbed to compensate for all of the disturbance sources and to mitigate jitter caused by in-band camera noise. The feedforward uses a novel robust least mean squares (RLMS) filter algorithm to reject the RWA and line frequency tones. High fidelity models of the sensors, disturbances and actuator are presented in this paper. These models were developed as part of a simulation of the LOS control system. Performance results from the hardware testbed at the Jet Propulsion Laboratory (JPL) are discussed in this paper.

Shields, Joel↗
NASA NTRS2003

Catalyzed Ignition of Bipropellants in Microtubes

This paper addresses the need to understand the physics and chemistry involved in propellant combustion processes in micro-scale combustors for propulsion systems on micro-spacecraft. These spacecraft are planned to have a mass less than 50 kilograms with attitude control estimated to be in the 10 milli-Newton thrust class. These combustors are anticipated to be manufactured using Micro Electrical Mechanical Systems (MEMS) technology and are expected to have diameters approaching the quenching diameter of the propellants. Combustors of this size are expected to benefit significantly from surface catalysis processes. Miniature flame tube apparatus is chosen for this study because microtubes can be easily fabricated from known catalyst materials and their simplicity in geometry can be used in fundamental simulations to more carefully characterize the measured heat transfer and pressure losses for validation purposes. Experimentally, we investigate the role of catalytically active surfaces within 0.4 and 0.8 mm internal diameter micro-tubes, with special emphases on ignition and extinction processes in fuel rich gaseous hydrogen and gaseous oxygen. Flame thickness and reaction zone thickness calculations predict that the diameters of our test apparatus are below the quenching diameter of the propellants in sub-atmospheric tests. Temperature and pressure rises in resistively heated platinum and palladium micro-tubes are used as an indication of exothermic reactions. Specific data on mass flow versus preheat temperature required to achieve ignition are presented.

Schneider, Steven J.↗
NASA NTRS2011

Solar Dynamics Observatory Guidance, Navigation, and Control System Overview

The Solar Dynamics Observatory (SDO) was designed and built at the Goddard Space Flight Center, launched from Cape Canaveral on February 11, 2010, and reached its final geosynchronous science orbit on March 16, 2010. The purpose of SDO is to observe the Sun and continuously relay data to a dedicated ground station. SDO remains Sun-pointing throughout most of its mission for the instruments to take measurements of the Sun. The SDO attitude control system (ACS) is a single-fault tolerant design. Its fully redundant attitude sensor complement includes sixteen coarse Sun sensors (CSSs), a digital Sun sensor (DSS), three two-axis inertial reference units (IRUs), and two star trackers (STs). The ACS also makes use of the four guide telescopes included as a part of one of the science instruments. Attitude actuation is performed using four reaction wheels assemblies (RWAs) and eight thrusters, with a single main engine used to provide velocity-change thrust for orbit raising. The attitude control software has five nominal control modes, three wheel-based modes and two thruster-based modes. A wheel-based Safehold running in the attitude control electronics box improves the robustness of the system as a whole. All six modes are designed on the same basic proportional-integral-derivative attitude error structure, with more robust modes setting their integral gains to zero. This paper details the final overall design of the SDO guidance, navigation, and control (GN&C) system and how it was used in practice during SDO launch, commissioning, and nominal operations. This overview will include the ACS control modes, attitude determination and sensor calibration, the high gain antenna (HGA) calibration, and jitter mitigation operation. The Solar Dynamics Observatory mission is part of the NASA Living With a Star program, which seeks to understand the changing Sun and its effects on the Solar System, life, and society. To this end, the SDO spacecraft carries three Sun-observing instruments: Helioseismic and Magnetic Imager (HMI), led by Stanford University; Atmospheric Imaging Assembly (AIA), led by Lockheed Martin Space and Astrophysics Laboratory; and Extreme Ultraviolet Variability Experiment (EVE), led by the University of Colorado. The basic mission is to observe the Sun for a very high percentage of the 5-year mission (10-year goal) with long stretches of uninterrupted observations and with constant, high-data-rate transmission to a dedicated ground station to be located in White Sands, New Mexico. These goals guided the design of the spacecraft bus that will carry and service the three-instrument payload. Overarching design goals for the bus are geosynchronous orbit, near-constant Sun observations with the ability to fly through eclipses, and constant HGA contact with the dedicated ground station. A three-axis stabilized ACS is needed both to point at the Sun accurately and to keep the roll about the Sun vector correctly positioned with respect to the solar north pole. This roll control is especially important for the magnetic field imaging of HM I. The mission requirements have several general impacts on the ACS design. Both the AIA and HMI instruments are very sensitive to the blurring caused by jitter. Each has an image stabilization system (ISS) with some ability to filter out high frequency motion, but below the bandwidth of the ISS the control system must compensate for disturbances within the ACS bandwidth or avoid exciting jitter at higher frequencies. Within the ACS bandwidth, the control requirement imposed by AIA is to place the center of the solar disk no more than 2 arc sec, 3 , from a body-defined target based on one of the GTs that accompany the instrument. This body-defined target, called the science reference boresight (SRB), was determined from the postlaunch orientation of the GTs by averaging the bounding telescope boresights for pitch to get a pitch SRB coordinate, and by averaging the bounding boresights for yaw toet the yaw SRB coordinate. The location of this SRB in the 0.5-deg field-of-view for each GT then becomes the central target for each telescope; one GT is selected for use as the ACS controlling guide telescope (CGT) at any given time. Fine Sun-pointing is effected based on this SRB for all three instruments when the Sun is within the linear range of the CGT. In addition to limiting jitter, HMI science requires averaging several observations, making the instrument sensitive to low frequency motion that induces differential motion between each observation. This requires the spacecraft attitude to be stable about the roll axis to approximately 10 arcsec over a ten-minute period. Instrument calibrations require that the spacecraft point the SRB up to 2.5 degrees in pitch and yaw away from the center of the Sun, placing the Sun outside the field-of-view of the guide telescopes. In such instances, when the GTs cannot provide the definitive target for the ACS, on-board attitude determination combined with ephemeris prediction of the Sun direction must provide the definitive target. EVE is capable of observing the Sun with less dependence on attitude control. However, the ground data processing needs for calibrations result in the most strict attitude knowledge requirements for the mission: [35,70,70] arcsec, 3 , of knowledge with respect to the center of the solar disk. In addition to driving the ACS sensor selection, the knowledge requirements, which have their effect primarily during Inertial mode calibrations, drive the accuracy requirements for the solar ephemeris. The need to achieve and maintain geosynchronous orbit (GEO) drove the need for high-efficiency propulsive systems and appropriate attitude control. The main engine provided high specific impulse for the maneuvers to attain GEO, while the smaller ACS thrusters managed the disturbance torques of the larger engine and provided the capability for much smaller adjustment burns on orbit. SDO s large solar profile means that solar radiation pressure is a large torque disturbance, and the momentum buildup from this disturbance and the GEO altitude drives the ACS to use thrusters to manage vehicle momentum. The demanding data capture budget for the mission, however, requires SDO to avoid frequent thruster maneuvers, while concerns about on-orbit jitter restrict the maximum desired wheel speeds desired from the RWAs. The plan for on-orbit wheel speed and momentum management will be discussed as well as what is now being done in operation after the jitter environment was characterized. The SDO ACS hardware complement is single-fault tolerant. Two main processors carry virtually identical copies of the command and data handling and ACS software, and two identical attitude control electronics (ACE) boxes carry Coldfire processors with contingency ACS software and other hardware interface cards; the ACE structure allows reaction wheels to be commanded by the Sun-pointing Safehold independent of the Mil Std 1553 data bus. The sixteen Adcole CSSs are grouped into primary and backup sets of eight sensors, each set providing the ability to calculate a sun vector. Each set of eight eyes provides full 4 -steradian coverage. The Adcole DSS comprises an optics head and a separate electronics box providing a 1553 data interface. The electronics box is mounted inside the Faraday cage created by the spacecraft bus module. The DSS head with its 32- deg square FOV is mounted on the instrument module with its boresight along the spacecraft X axis, nearly aligned with the Sun during observations. Adcole has designed the DSS calibration parameters so that the accuracy is 0.24 arcminutes within 10 deg of the boresight, and diminishes to 3 arcminutes as the Sun moves towards the edges of its FOV . This DSS calibration scheme provides higher accuracy attitude determination over the range of the instrument calibration maneuvers.

Morgenstern, Wendy M.↗
NASA NTRS2001

Thermal Analysis for Orbiter and ISS Plume Impingement on International Space Station

The NASA Reaction Control System (RCS) Plume Model (RPM) is an exhaust plume flow field and impingement heating code that has been updated and applied to components of the International Space Station (ISS). The objective of this study was to use this code to determine if plume environments from either Orbiter PRCS jets or ISS reboost and Attitude Control System (ACS) jets cause thermal issues on ISS component surfaces. This impingement analysis becomes increasingly important as the ISS is being assembled with its first permanent crew scheduled to arrive by the end of fall 2000. By early summer 2001 , the ISS will have a number of major components installed such as the Unity (Node 1), Destiny (Lab Module), Zarya (Functional Cargo Block), and Zvezda (Service Module) along with the P6 solar arrays and radiators and the Z-1 truss. Plume heating to these components has been analyzed with the RPM code as well as additional components for missions beyond Flight 6A such as the Propulsion Module (PM), Mobile Servicing System, Space Station Remote Manipulator System, Node 2, and the Cupola. For the past several years NASA/JSC has been developing the methodology to predict plume heating on ISS components. The RPM code is a modified source flow code with capabilities for scarfed nozzles and intersecting plumes that was developed for the 44 Orbiter RCS jets. This code has been validated by comparison with Shuttle Plume Impingement Flight Experiment (SPIFEX) heat flux and pressure data and with CFD and Method of Characteristics solutions. Previous analyses of plume heating predictions to the ISS using RPM have been reported, but did not consider thermal analysis for the components nor jet-firing histories as the Orbiter approaches the ISS docking ports. The RPM code has since been modified to analyze surface temperatures with a lumped mass approach and also uses jet-firing histories to produce pulsed heating rates. In addition, RPM was modified to include plume heating from ISS jets to ISS components where the jet coordinates are specified, together with the engine cant angle. These latter studies have been focused on the PM with plumes from its reboost and ACS jets impinging on various ISS components and also focused on the Japanese H2 Transfer Vehicle (HTV) with the plumes from its reboost engines impinging on the Cupola window. This paper will present plume heating and surface temperature results on a number of ISS components with and without jet-firing histories, evaluate post-flight data, and describe any potential thermal issues

Rochelle, William C.↗
NASA NTRS2011

Cryogenic Propellant Feed System Analytical Tool Development

The Propulsion Systems Branch at NASA s Lyndon B. Johnson Space Center (JSC) has developed a parametric analytical tool to address the need to rapidly predict heat leak into propellant distribution lines based on insulation type, installation technique, line supports, penetrations, and instrumentation. The Propellant Feed System Analytical Tool (PFSAT) will also determine the optimum orifice diameter for an optional thermodynamic vent system (TVS) to counteract heat leak into the feed line and ensure temperature constraints at the end of the feed line are met. PFSAT was developed primarily using Fortran 90 code because of its number crunching power and the capability to directly access real fluid property subroutines in the Reference Fluid Thermodynamic and Transport Properties (REFPROP) Database developed by NIST. A Microsoft Excel front end user interface was implemented to provide convenient portability of PFSAT among a wide variety of potential users and its ability to utilize a user-friendly graphical user interface (GUI) developed in Visual Basic for Applications (VBA). The focus of PFSAT is on-orbit reaction control systems and orbital maneuvering systems, but it may be used to predict heat leak into ground-based transfer lines as well. PFSAT is expected to be used for rapid initial design of cryogenic propellant distribution lines and thermodynamic vent systems. Once validated, PFSAT will support concept trades for a variety of cryogenic fluid transfer systems on spacecraft, including planetary landers, transfer vehicles, and propellant depots, as well as surface-based transfer systems. The details of the development of PFSAT, its user interface, and the program structure will be presented.

Lusby, Brian S.↗