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NASA NTRS2005

Design and Qualification of the AMS-02 Flight Cryocoolers

Four commercial Sunpower M87N Stirling-cycle cryocoolers will be used to extend the lifetime of the Alpha Magnetic Spectrometer-02 (AMS-02) experiment. The cryocoolers will be mounted to the AMS-02 vacuum case using a structure that will thermally and mechanically decouple the cryocooler from the vacuum case. This paper discusses modifications of the Sunpower M87N cryocooler to make it acceptable for space flight applications and suitable for use on AMS-02. Details of the flight model qualification test program are presented. AMS-02 is a state-of-the-art particle physics detector containing a large superfluid helium-cooled superconducting magnet. Highly sensitive detector plates inside the magnet measure a particle's speed, mass, charge, and direction. The AMS-02 experiment, which will be flown as an attached payload on the International Space Station, will study the properties and origin of cosmic particles and nuclei including antimatter and dark matter. Two engineering model cryocoolers have been under test at NASA Goddard since November 2001. Qualification testing of the engineering model cryocooler bracket assembly including random vibration and thermal vacuum testing was completed at the end of April 2005. The flight cryocoolers were received in December 2003. Acceptance testing of the flight cryocooler bracket assemblies began in May 2005 .

Shirey, Kimberly↗

NASA NTRS2005

Force Limited Vibration Testing

This slide presentation reviews the concept and applications of Force Limited Vibration Testing. The goal of vibration testing of aerospace hardware is to identify problems that would result in flight failures. The commonly used aerospace vibration tests uses artificially high shaker forces and responses at the resonance frequencies of the test item. It has become common to limit the acceleration responses in the test to those predicted for the flight. This requires an analysis of the acceleration response, and requires placing accelerometers on the test item. With the advent of piezoelectric gages it has become possible to improve vibration testing. The basic equations have are reviewed. Force limits are analogous and complementary to the acceleration specifications used in conventional vibration testing. Just as the acceleration specification is the frequency spectrum envelope of the in-flight acceleration at the interface between the test item and flight mounting structure, the force limit is the envelope of the in-flight force at the interface . In force limited vibration tests, both the acceleration and force specifications are needed, and the force specification is generally based on and proportional to the acceleration specification. Therefore, force limiting does not compensate for errors in the development of the acceleration specification, e.g., too much conservatism or the lack thereof. These errors will carry over into the force specification. Since in-flight vibratory force data are scarce, force limits are often derived from coupled system analyses and impedance information obtained from measurements or finite element models (FEM). Fortunately, data on the interface forces between systems and components are now available from system acoustic and vibration tests of development test models and from a few flight experiments. Semi-empirical methods of predicting force limits are currently being developed on the basis of the limited flight and system test data. A simple two degree of freedom system is shown and the governing equations for basic force limiting results for this system are reviewed. The design and results of the shuttle vibration forces (SVF) experiments are reviewed. The Advanced Composition Explorer (ACE) also was used to validate force limiting. Test instrumentation and supporting equipment are reviewed including piezo-electric force transducers, signal processing and conditioning systems, test fixtures, and vibration controller systems. Several examples of force limited vibration testing are presented with some results.

random vibration testing↗

NASA NTRS2018

Global Ecosystem Dynamics Investigation (GEDI) Structural Verification Unit (SVU) Vibration Test

This presentation describes the vibration test campaign of the Structural Verification Unit for the Global Ecosystem Dynamics Investigation (GEDI) mission The Structural Verification Unit test campaign served multiple purposes including the qualification of the instrument primary structure, verification of the structure's stiffness, Aperture Control Mechanism assembly level verification, and validation of the control approach for protoflight instrument vibration testing. Testing included three axes of sine burst, random, and sine vibration excitation. This test sequence required a high number of response instrumentation sensors that included tri-axial accelerometers and tri-axial force gauges. Multiple response limiting methods that included acceleration, force, and moment measurements were used to ensure the safety of the flight hardware. The lessons and specific test details learned on the structural verification unit test campaign will reduce test risks for the upcoming instrument-level vibration tests.

Structural Verification Unit↗

NASA NTRS1996

Is the Non-Dipole Magnetic Field Random?

Statistical modelling of the Earth's magnetic field B has a long history. In particular, the spherical harmonic coefficients of scalar fields derived from B can be treated as Gaussian random variables. In this paper, we give examples of highly organized fields whose spherical harmonic coefficients pass tests for independent Gaussian random variables. The fact that coefficients at some depth may be usefully summarized as independent samples from a normal distribution need not imply that there really is some physical, random process at that depth. In fact, the field can be extremely structured and still be regarded for some purposes as random. In this paper, we examined the radial magnetic field B(sub r) produced by the core, but the results apply to any scalar field on the core-mantle boundary (CMB) which determines B outside the CMB.

Walker, Andrew D.↗

NASA NTRS1979

Electrical Evaluation of RCA MWS5001D Random Access Memory, Volume 3, Appendix B

The electrical characterization and qualification test results are presented for the RCA MWS5001D random access memory. The tests included functional tests, AC and DC parametric tests, AC parametric worst-case pattern selection test, determination of worst-case transition for setup and hold times, and a series of schmoo plots. The test values for the output voltage, average input current, the supply current and the leakage current are presented.

Klute, A.↗

NASA NTRS1979

Electrical Evaluation of RCA MWS5001D Random Access Memory, Volume 4, Appendix C

The electrical characterization and qualification test results are presented for the RCA MWS5001D random access memory. The tests included functional tests, AC and DC parametric tests, AC parametric worst-case pattern selection test, determination of worst-case transition for setup and hold times, and a series of schmoo plots. Statistical analysis data is supplied along with write pulse width, read cycle time, write cycle time, and chip enable time data.

Klute, A.↗

NASA NTRS1979

Electrical Evaluation of RCA MWS5001D Random Access Memory, Volume 1

Electrical characterization and qualification tests were performed on the RCA MWS5001D, 1024 by 1-bit, CMOS, random access memory. Characterization tests were performed on five devices. The tests included functional tests, AC parametric worst case pattern selection test, determination of worst-case transition for setup and hold times and a series of schmoo plots. The qualification tests were performed on 32 devices and included a 2000 hour burn in with electrical tests performed at 0 hours and after 168, 1000, and 2000 hours of burn in. The tests performed included functional tests and AC and DC parametric tests. All of the tests in the characterization phase, with the exception of the worst-case transition test, were performed at ambient temperatures of 25, -55 and 125 C. The worst-case transition test was performed at 25 C. The preburn in electrical tests were performed at 25, -55, and 125 C. All burn in endpoint tests were performed at 25, -40, -55, 85, and 125 C.

Klute, A.↗

NASA NTRS1994

Experimental analysis of thread movement in bolted connections due to vibrations

The objective of this study was to identify the main design parameters contributing to loosening of bolts due to vibration and to identify their relative importance and degree of contribution to bolt loosening. Vibration testing was conducted on a shaketable with a controlled-random input in the dynamic testing laboratory of the Structural Test Division of MSFC. Test specimens which contained one test bolt were vibrated for a fixed amount of time and percentage of pre-load loss was measured. Each specimen tested implemented some combination of eleven design parameters as dictated by the design of experiment methodology employed. The eleven design parameters were: bolt size (diameter), lubrication on bolt, hole tolerance, initial pre-load, nut locking device, grip length, thread pitch, lubrication between mating materials, class of fit, joint configuration and mass of configuration. These parameters were chosen for this experiment because they are believed to be the design parameters having the greatest impact on bolt loosening. Two values of each design parameter were used and each combination of parameters tested was subjected to two different directions of vibration and two different g-levels of vibration. One replication was made for each test to gain some indication of experimental error and repeatability and to give some degree of statistical credibility to the data, resulting in a total of 96 tests being performed. The results of the investigation indicated that nut locking devices, joint configuration, fastener size, and mass of configuration were significant in bolt loosening due to vibration. The results of this test can be utilized to further research the complex problem of bolt loosening due to vibration.

Ramey, G. ED↗

NASA NTRS1995

Experimental analysis of thread movement in bolted connections due to vibrations

This is the final report of research project NAS8-39131 #33 sponsored by NASA's George C. Marshall Space Flight Center (MSFC) and carried out by the Civil Engineering Department of Auburn University (Auburn, Alabama) and personnel of MSFC. The objective of this study was to identify the main design parameters contributing to the loosening of bolts due to vibration and to identify their relative importance and degree of contribution to bolt loosening. Vibration testing was conducted on a shaketable with a controlled-random input in the dynamic testing laboratory of the Structural Test Division of MSFC. Test specimens which contained one test bolt were vibrated for a fixed amount of time and a percentage of pre-load loss was measured. Each specimen tested implemented some combination of eleven design parameters as dictated by the design of experiment methodology employed. The eleven design parameters were: bolt size (diameter), lubrication on bolt, hole tolerance, initial pre-load, nut locking device, grip length, thread pitch, lubrication between mating materials, class of fit, joint configuration, and mass of configuration. These parameters were chosen for this experiment because they are believed to be the design parameters having the greatest impact on bolt loosening. Two values of each design parameter were used and each combination of parameters tested was subjected to two different directions of vibration and two different g-levels of vibration. One replication was made for each test to gain some indication of experimental error and repeatability and to give some degree of statistical credibility to the data, resulting in a total of 96 tests being performed. The results of the investigation indicated that nut locking devices, joint configuration, fastener size, and mass of configuration were significant in bolt loosening due to vibration. The results of this test can be utilized to further research the complex problem of bolt loosening due to vibration.

Ramsey, G. ED↗

NASA NTRS1979

Electrical Evaluation of RCA MWS5001D Random Access Memory, Volume 5, Appendix D

The electrical characterization and qualification test results are presented for the RCA MWS 5001D random access memory. The tests included functional tests, AC and DC parametric tests, AC parametric worst-case pattern selection test, determination of worst-case transition for setup and hold times, and a series of schmoo plots. Average input high current, worst case input high current, output low current, and data setup time are some of the results presented.

Klute, A.↗

NASA NTRS2012

Characterization of Friction Joints Subjected to High Levels of Random Vibration

This paper describes the test program in detail including test sample description, test procedures, and vibration test results of multiple test samples. The material pairs used in the experiment were Aluminum-Aluminum, Aluminum- Dicronite coated Aluminum, and Aluminum-Plasmadize coated Aluminum. Levels of vibration for each set of twelve samples of each material pairing were gradually increased until all samples experienced substantial displacement. Data was collected on 1) acceleration in all three axes, 2) relative static displacement between vibration runs utilizing photogrammetry techniques, and 3) surface galling and contaminant generation. This data was used to estimate the values of static friction during random vibratory motion when "stick-slip" occurs and compare these to static friction coefficients measured before and after vibration testing.

aluminum↗

NASA NTRS2010

Random vs. Combinatorial Methods for Discrete Event Simulation of a Grid Computer Network

This study compared random and t-way combinatorial inputs of a network simulator, to determine if these two approaches produce significantly different deadlock detection for varying network configurations. Modeling deadlock detection is important for analyzing configuration changes that could inadvertently degrade network operations, or to determine modifications that could be made by attackers to deliberately induce deadlock. Discrete event simulation of a network may be conducted using random generation, of inputs. In this study, we compare random with combinatorial generation of inputs. Combinatorial (or t-way) testing requires every combination of any t parameter values to be covered by at least one test. Combinatorial methods can be highly effective because empirical data suggest that nearly all failures involve the interaction of a small number of parameters (1 to 6). Thus, for example, if all deadlocks involve at most 5-way interactions between n parameters, then exhaustive testing of all n-way interactions adds no additional information that would not be obtained by testing all 5-way interactions. While the maximum degree of interaction between parameters involved in the deadlocks clearly cannot be known in advance, covering all t-way interactions may be more efficient than using random generation of inputs. In this study we tested this hypothesis for t = 2, 3, and 4 for deadlock detection in a network simulation. Achieving the same degree of coverage provided by 4-way tests would have required approximately 3.2 times as many random tests; thus combinatorial methods were more efficient for detecting deadlocks involving a higher degree of interactions. The paper reviews explanations for these results and implications for modeling and simulation.

Kuhn, D. Richard↗

NASA NTRS1990

Oscillating flow loss test results in Stirling engine heat exchangers

The results are presented for a test program designed to generate a database of oscillating flow loss information that is applicable to Stirling engine heat exchangers. The tests were performed on heater/cooler tubes of various lengths and entrance/exit configurations, on stacked and sintered screen regenerators of various wire diameters and on Brunswick and Metex random fiber regenerators. The test results were performed over a range of oscillating flow parameters consistent with Stirling engine heat exchanger experience. The tests were performed on the Sunpower oscillating flow loss rig which is based on a variable stroke and variable frequency linear drive motor. In general, the results are presented by comparing the measured oscillating flow losses to the calculated flow losses. The calculated losses are based on the cycle integration of steady flow friction factors and entrance/exit loss coefficients.

Koester, G.↗

NASA NTRS1986

Simulation efficiency in acoustic testing of Shuttle payloads

Comparative evaluations of payload vibration responses from ground acoustic tests and Shuttle flights of several payloads indicate that ground acoustic testing will generally underestimate the Shuttle flight vibrational response of a payload, particularly in the low frequency range. This underestimation is found to be primarily due to the lack of simulation during the acoustic test of the in-flight mechanical energy transmission normally transmitted through the Orbiter-payload structural interface. It is suggested that test efficiency corrections be applied when developing random vibration criteria based on ground acoustic test data.

On, Frank J.↗

NASA NTRS1986

Computer-aided analysis for the Mechanics of Granular Materials (MGM) experiment

The Mechanics of Granular Materials (MGM) program is planned to provide experimental determinations of the mechanics of granular materials under very low gravity conditions. The initial experiments will use small glass beads as the granular material, and a precise tracking of individual beads during the test is desired. Real-time video images of the experimental specimen were taken with a television camera, and subsequently digitized by a frame grabber installed in a microcomputer. Easily identified red tracer beads were randomly scattered throughout the test specimen. A set of Pascal programs was written for processing and analyzing the digitized images. Filtering the image with Laplacian, dilation, and blurring filters when using a threshold function produced a binary (black on white) image which clearly identified the red beads. The centroids and areas for each bead were then determined. Analyzing a series of the images determined individual red bead displacements throughout the experiment. The system can provide displacement accuracies on the order of 0.5 to 1 pixel is the image is taken directly from the video camera. Digitizing an image from a video cassette recorder introduces an additional repeatability error of 0.5 to 1 pixel. Other programs were written to provide hardcopy prints of the digitized images on a dot-matrix printer.

Parker, Joey K.↗

NASA NTRS2010

Analysis of Wind Tunnel Polar Replicates Using the Modern Design of Experiments

The role of variance in a Modern Design of Experiments analysis of wind tunnel data is reviewed, with distinctions made between explained and unexplained variance. The partitioning of unexplained variance into systematic and random components is illustrated, with examples of the elusive systematic component provided for various types of real-world tests. The importance of detecting and defending against systematic unexplained variance in wind tunnel testing is discussed, and the random and systematic components of unexplained variance are examined for a representative wind tunnel data set acquired in a test in which a missile is used as a test article. The adverse impact of correlated (non-independent) experimental errors is described, and recommendations are offered for replication strategies that facilitate the quantification of random and systematic unexplained variance.

Deloach, Richard↗

NASA NTRS2001

Structural Qualification Testing of the WindSat Payload Using Sine Bursts Near Structural Resonance

Sine burst tests are often used for structural qualification of space flight hardware. In most instances, the driving frequency of the shaker is specified far below the structure's first resonant mode, such that the entire test article sees uniform acceleration. For large structures, this limits qualification testing to lower parts of the structure, or else it over-tests the lower structure to achieve qualification of the upper structure. The WindSat payload, a 10.5 foot tall graphite/epoxy, titanium, and aluminum radiometer, experiences accelerations at the six foot diameter reflector nearly four times that at the spacecraft interface. Due to size of the payload, the number of bonded joints, and the lightweight reflector support structure design and construction, using static pull testing to qualify all of the bonded joints in the upper structure would result in large, expensive, and extensive test fixturing. Sine burst testing near the first two structural resonant modes was performed on the WindSat payload to achieve the correct load factor distribution up the stack for structural qualification. In this presentation, how finite element method (FEM) sine burst predictions were used in conjunction with low level random and sine burst tests to achieve correct qualification test load factor distribution on the WindSat payload is discussed. Also presented is the risk mitigation approach for using the uncorrelated FEM in this procedure.

Pontius, Jim↗

NASA NTRS1978

Modal confidence factor in vibration testing

The theory and applications of a time domain modal test technique are presented. The method uses free decay of random responses from a structure under test to identify its modal characteristics namely, natural frequencies, damping factors, and mode shapes. The method can identify multimodal (highly coupled) systems and modes that have very small contribution in the responses. A method is presented to decrease the effects of high levels of noise in the data and thus improve the accuracy of identified parameters. This is accomplished using an oversized mathematical model. The concept of modal confidence factor (MCF) is developed. The MCF is a number calculated for every identified mode for a structure under test. The MCF varies from 0.000 for a distorted, nonlinear, or noise mode to 100.0 for a pure structural mode. The theory of the MCF is based on the correlation that exits between the modal deflection at a certain station and the modal deflection at the same station delayed in time. The theory and application of the MCF is illustrated by two experiments. The first experiment deals with simulated responses from a two degree of freedom system with 20 percent, 40 percent, and 100 percent noise added. The second experiment was run on a generalized payload model. The free decay response from the payload model contained about 22 percent noise.

Ibrahim, S. R.↗