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NASA NTRS2010

Understanding the Space Shuttle Main Engine Hydraulic Actuation System and Reviewing Its Evolution

The complex engine start and thrust control requirements of the Space Shuttle Main Engine (SSME) require unique valve, actuator and control system hardware. The Hydraulic Actuation System (HAS) was designed, developed, and now operates to meet tight engine control requirement limits to assure safe, reliable and correct engine thrust at all times. The actuator is designed to be fail safe and fail operate in the areas where redundancy is important. The HAS has an additional pneumatic operating capability that insures a safe sequential closure of all actuators and propellant valves in the event of the loss of hydraulic system pressure or loss of electrical closed loop control of the actuator. The objective of this paper is to provide a complete description of the actuator s internal operating system, along with its interaction with all SSME system interfaces. Additionally the paper addresses the challenges, problems identified, and corrected, and lessons learned, during the course of the almost 35 years of engine operation.

McWade, Robert J.↗

NASA NTRS1997

Automated Test Systems for Toxic Vapor Detectors

The NASA Toxic Vapor Detection Laboratory (TVDL) at the Kennedy Space Center (KSC), Florida, has been using Personal Computer based Data Acquisition and Control Systems (PCDAS) for about nine years. These systems control the generation of toxic vapors of known concentrations under controlled conditions of temperature and humidity. The PCDAS also logs the test conditions and the test article responses in data files for analysis by standard spreadsheets or custom programs. The PCDAS was originally developed to perform standardized qualification and acceptance tests in a search for a commercial off-the-shelf (COTS) toxic vapor detector to replace the hydrazine detectors for the Space Shuttle launch pad. It has since become standard test equipment for the TVDL and is indispensable in producing calibration standards for the new hydrazine monitors at the 10 part per billion (ppb) level. The standard TVDL PCDAS can control two toxic vapor generators (TVG's) with three channels each and two flow/temperature/humidity (FIFH) controllers and it can record data from up to six toxic vapor detectors (TVD's) under test and can deliver flows from 5 to 50 liters per minute (L/m) at temperatures from near zero to 50 degrees Celsius (C) using an environmental chamber to maintain the sample temperature. The concentration range for toxic vapors depends on the permeation source installed in the TVG. The PCDAS can provide closed loop control of temperature and humidity to two sample vessels, typically one for zero gas and one for the standard gas. This is required at very low toxic vapor concentrations to minimize the time required to passivate the sample delivery system. Recently, there have been several requests for information about the PCDAS by other laboratories with similar needs, both on and off KSC. The purpose of this paper is to inform the toxic vapor detection community of the current status and planned upgrades to the automated testing of toxic vapor detectors at the Kennedy Space Center.

Mattson, C. B.↗

NASA NTRS1997

Automated Test Systems for Toxic Vapor Detectors

The NASA Toxic Vapor Detection Laboratory (TVDL) at the Kennedy Space Center (KSC), Florida, has been using Personal Computer based Data Acquisition and Control Systems (PCDAS) for about nine years. These systems control the generation of toxic vapors of known concentrations under controlled conditions of temperature and humidity. The PCDAS also logs the test conditions and the test article responses in data files for analysis by standard spreadsheets or custom programs. The PCDAS was originally developed to perform standardized qualification and acceptance tests in a search for a commercial off-the-shelf (COTS) toxic vapor detector to replace the hydrazine detectors for the Space Shuttle launch pad. It has since become standard test equipment for the TVDL and is indispensable in producing calibration standards for the new hydrazine monitors at the 10 part per billion (ppb) level. The standard TVDL PCDAS can control two toxic vapor generators (TVG's) with three channels each and two flow/ temperature / humidity (FTH) controllers and it can record data from up to six toxic vapor detectors (TVD's) under test and can deliver flows from 5 to 50 liters per minute (L/m) at temperatures from near zero to 50 degrees Celsius (C) using an environmental chamber to maintain the sample temperature. The concentration range for toxic vapors depends on the permeation source installed in the TVG. The PCDAS can provide closed loop control of temperature and humidity to two sample vessels, typically one for zero gas and one for the standard gas. This is required at very low toxic vapor concentrations to minimize the time required to passivate the sample delivery system. Recently, there have been several requests for information about the PCDAS by other laboratories with similar needs, both on and off KSC. The purpose of this paper is to inform the toxic vapor detection community of the current status and planned upgrades to the automated testing of toxic vapor detectors at the Kennedy Space Center.

Mattson, C. B.↗

NASA NTRS1998

Active Pattern Factor Control for Gas Turbine Engines

Small variations in fuel/air mixture ratios within gas turbine combustors can result in measurable, and potentially detrimental, exit thermal gradients. Thermal gradients can increase emissions, as well as shorten the design life of downstream turbomachinery, particularly stator vanes. Uniform temperature profiles are usually sought through careful design and manufacturing of related combustor components. However, small componentto-component variations as well as numerous aging effects degrade system performance. To compensate for degraded thermal performance, researchers are investigating active, closed-loop control schemes.

May, James E.↗

NASA NTRS2001

Integral Twist Actuation of Helicopter Rotor Blades for Vibration Reduction

Active integral twist control for vibration reduction of helicopter rotors during forward flight is investigated. The twist deformation is obtained using embedded anisotropic piezocomposite actuators. An analytical framework is developed to examine integrally-twisted blades and their aeroelastic response during different flight conditions: frequency domain analysis for hover, and time domain analysis for forward flight. Both stem from the same three-dimensional electroelastic beam formulation with geometrical-exactness, and axe coupled with a finite-state dynamic inflow aerodynamics model. A prototype Active Twist Rotor blade was designed with this framework using Active Fiber Composites as the actuator. The ATR prototype blade was successfully tested under non-rotating conditions. Hover testing was conducted to evaluate structural integrity and dynamic response. In both conditions, a very good correlation was obtained against the analysis. Finally, a four-bladed ATR system is built and tested to demonstrate its concept in forward flight. This experiment was conducted at NASA Langley T~ansonic Dynamics Tunnel and represents the first-of-a-kind Mach-scaled fully-active-twist rotor system to undergo forward flight test. In parallel, the impact upon the fixed- and rotating-system loads is estimated by the analysis. While discrepancies are found in the amplitude of the loads under actuation, the predicted trend of load variation with respect to its control phase correlates well. It was also shown, both experimentally and numerically, that the ATR blade design has the potential for hub vibratory load reduction of up to 90% using individual blade control actuation. Using the numerical framework, system identification is performed to estimate the harmonic transfer functions. The linear time-periodic system can be represented by a linear time-invariant system under the three modes of blade actuation: collective, longitudinal cyclic, and lateral cyclic. A vibration minimizing controller is designed based on this result, which implements classical disturbance rejection algorithm with some modifications. The controller is simulated numerically, and more than 90% of the 4P hub vibratory load is eliminated. By accomplishing the experimental and analytical steps described in this thesis, the present concept is found to be a viable candidate for future generation low-vibration helicopters. Also, the analytical framework is shown to be very appropriate for exploring active blade designs, aeroelastic behavior prediction, and as simulation tool for closed-loop controllers.

Shin, SangJoon↗

NASA NTRS1972

Integrated dynamic analysis simulation of space stations with controllable solar array

A methodology is formulated and presented for the integrated structural dynamic analysis of space stations with controllable solar arrays and non-controllable appendages. The structural system flexibility characteristics are considered in the dynamic analysis by a synthesis technique whereby free-free space station modal coordinates and cantilever appendage coordinates are inertially coupled. A digital simulation of this analysis method is described and verified by comparison of interaction load solutions with other methods of solution. Motion equations are simulated for both the zero gravity and artificial gravity (spinning) orbital conditions. Closed loop controlling dynamics for both orientation control of the arrays and attitude control of the space station are provided in the simulation by various generic types of controlling systems. The capability of the simulation as a design tool is demonstrated by utilizing typical space station and solar array structural representations and a specific structural perturbing force. Response and interaction load solutions are presented for this structural configuration and indicate the importance of using an integrated type analysis for the predictions of structural interactions.

Heinrichs, J. A.↗

NASA NTRS1992

Modeling and control study of the NASA 0.3-meter transonic cryogenic tunnel for use with sulfur hexafluoride medium

The NASA Langley 0.3-m Transonic Cryogenic Tunnel is to be modified to operate with sulfur hexafluoride gas while retaining its present capability to operate with nitrogen. The modified tunnel will provide high Reynolds number flow on aerodynamic models with two different test gases. The document details a study of the SF6 tunnel performance boundaries, thermodynamic modeling of the tunnel process, nonlinear dynamical simulation of math model to yield tunnel responses, the closed loop control requirements, control laws, and mechanization of the control laws on the microprocessor based controller.

Balakrishna, S.↗

NASA NTRS1994

Control of maglev vehicles with aerodynamic and guideway disturbances

A modeling, analysis, and control design methodology is presented for maglev vehicle ride quality performance improvement as measured by the Pepler Index. Ride quality enhancement is considered through active control of secondary suspension elements and active aerodynamic surfaces mounted on the train. To analyze and quantify the benefits of active control, the authors have developed a five degree-of-freedom lumped parameter model suitable for describing a large class of maglev vehicles, including both channel and box-beam guideway configurations. Elements of this modeling capability have been recently employed in studies sponsored by the U.S. Department of Transportation (DOT). A perturbation analysis about an operating point, defined by vehicle and average crosswind velocities, yields a suitable linearized state space model for multivariable control system analysis and synthesis. Neglecting passenger compartment noise, the ride quality as quantified by the Pepler Index is readily computed from the system states. A statistical analysis is performed by modeling the crosswind disturbances and guideway variations as filtered white noise, whereby the Pepler Index is established in closed form through the solution to a matrix Lyapunov equation. Data is presented which indicates the anticipated ride quality achieved through various closed-loop control arrangements.

Flueckiger, Karl↗

NASA NTRS1981

Simulation of Heavy Lift Airship dynamics over large ranges of incidence and speed

A nonlinear, multibody, six-degrees-of-freedom digital simulation has been developed to study generic Heavy Lift Airship (HLA) dynamics and control. The basic aerodynamic functions developed to model the hull, tail, and rotor loads continuously over all incidence ranges are reviewed and applied to a Quadrotor HLA with a low fineness ratio hull and a small vee-tail. Trim calculations for a test vehicle suggest control power deficiencies in crosswind stationkeeping for the unloaded vehicle. Gust responses show the importance of correctly calculating loads due to accelerated relative motion of air and hull. Numerically linearized dynamics for the test vehicle show the existence of a divergent yaw mode, and an oscillatory pitch mode whose stability characteristics are sensitive to flight speed. A considerable improvement in the vehicle's stability and response results from a simple multi-axis closed-loop control system operating on the rotors and propeller blades.

Tischler, M. B.↗

NASA NTRS2012

Image Mapping and Visual Attention on the Sensory Ego-Sphere

The Sensory Ego-Sphere (SES) is a short-term memory for a robot in the form of an egocentric, tessellated, spherical, sensory-motor map of the robot s locale. Visual attention enables fast alignment of overlapping images without warping or position optimization, since an attentional point (AP) on the composite typically corresponds to one on each of the collocated regions in the images. Such alignment speeds analysis of the multiple images of the area. Compositing and attention were performed two ways and compared: (1) APs were computed directly on the composite and not on the full-resolution images until the time of retrieval; and (2) the attentional operator was applied to all incoming imagery. It was found that although the second method was slower, it produced consistent and, thereby, more useful APs. The SES is an integral part of a control system that will enable a robot to learn new behaviors based on its previous experiences, and that will enable it to recombine its known behaviors in such a way as to solve related, but novel, task problems with apparent creativity. The approach is to combine sensory-motor data association and dimensionality reduction to learn navigation and manipulation tasks as sequences of basic behaviors that can be implemented with a small set of closed-loop controllers. Over time, the aggregate of behaviors and their transition probabilities form a stochastic network. Then given a task, the robot finds a path in the network that leads from its current state to the goal. The SES provides a short-term memory for the cognitive functions of the robot, association of sensory and motor data via spatio-temporal coincidence, direction of the attention of the robot, navigation through spatial localization with respect to known or discovered landmarks, and structured data sharing between the robot and human team members, the individuals in multi-robot teams, or with a C3 center.

Fleming, Katherine Achim↗

NASA NTRS1997

Robust Flight Path Determination for Mars Precision Landing Using Genetic Algorithms

This paper documents the application of genetic algorithms (GAs) to the problem of robust flight path determination for Mars precision landing. The robust flight path problem is defined here as the determination of the flight path which delivers a low-lift open-loop controlled vehicle to its desired final landing location while minimizing the effect of perturbations due to uncertainty in the atmospheric model and entry conditions. The genetic algorithm was capable of finding solutions which reduced the landing error from 111 km RMS radial (open-loop optimal) to 43 km RMS radial (optimized with respect to perturbations) using 200 hours of computation on an Ultra-SPARC workstation. Further reduction in the landing error is possible by going to closed-loop control which can utilize the GA optimized paths as nominal trajectories for linearization.

Bayard, David S.↗

NASA NTRS2014

Additive Manufacturing Modeling and Simulation A Literature Review for Electron Beam Free Form Fabrication

Additive manufacturing is coming into industrial use and has several desirable attributes. Control of the deposition remains a complex challenge, and so this literature review was initiated to capture current modeling efforts in the field of additive manufacturing. This paper summarizes about 10 years of modeling and simulation related to both welding and additive manufacturing. The goals were to learn who is doing what in modeling and simulation, to summarize various approaches taken to create models, and to identify research gaps. Later sections in the report summarize implications for closed-loop-control of the process, implications for local research efforts, and implications for local modeling efforts.

Seufzer, William J.↗

NASA NTRS2015

Low-Power Operation and Plasma Characterization of a Qualification Model SPT-140 Hall Thruster for NASA Science Missions

Hall thruster systems based on commercial product lines can potentially lead to lower cost electric propulsion (EP) systems for deep space science missions. A 4.5-kW SPT-140 Hall thruster presently under qualification testing by SSL leverages the substantial heritage of the SPT-100 being flown on Russian and US commercial satellites. The Jet Propulsion Laboratory is exploring the use of commercial EP systems, including the SPT-140, for deep space science missions, and initiated a program to evaluate the SPT-140 in the areas of low power operation and thruster operating life. A qualification model SPT-140 designated QM002 was evaluated for operation and plasma properties along channel centerline, from 4.5 kW to 0.8 kW. Additional testing was performed on a development model SPT-140 designated DM4 to evaluate operation with a Moog proportional flow control valve (PFCV). The PFCV was commanded by an SSL engineering model PPU-140 Power Processing Unit (PPU). Performance measurements on QM002 at 0.8 kW discharge power were 50 mN of thrust at a total specific impulse of 1250 s, a total thruster efficiency of 0.38, and discharge current oscillations of under 3% of the mean current. Steady-state operation at 0.8 kW was demonstrated during a 27 h firing. The SPT-140 DM4 was operated in closed-loop control of the discharge current with the PFCV and PPU over discharge power levels of 0.8-4.5 kW. QM002 and DM4 test data indicate that the SPT-140 design is a viable candidate for NASA missions requiring power throttling down to low thruster input power.

Garner, Charles E.↗

NASA NTRS1983

A generalized computer code for developing dynamic gas turbine engine models (DIGTEM)

This paper describes DIGTEM (digital turbofan engine model), a computer program that simulates two spool, two stream (turbofan) engines. DIGTEM was developed to support the development of a real time multiprocessor based engine simulator being designed at the Lewis Research Center. The turbofan engine model in DIGTEM contains steady state performance maps for all the components and has control volumes where continuity and energy balances are maintained. Rotor dynamics and duct momentum dynamics are also included. DIGTEM features an implicit integration scheme for integrating stiff systems and trims the model equations to match a prescribed design point by calculating correction coefficients that balance out the dynamic equations. It uses the same coefficients at off design points and iterates to a balanced engine condition. Transients are generated by defining the engine inputs as functions of time in a user written subroutine (TMRSP). Closed loop controls can also be simulated. DIGTEM is generalized in the aerothermodynamic treatment of components. This feature, along with DIGTEM's trimming at a design point, make it a very useful tool for developing a model of a specific turbofan engine.

Daniele, C. J.↗

NASA NTRS1984

A generalized computer code for developing dynamic gas turbine engine models (DIGTEM)

Daniele, C. J.↗

NASA NTRS1989

Middeck Active Control Experiment (MACE), phase A

A rationale to determine which structural experiments are sufficient to verify the design of structures employing Controlled Structures Technology was derived. A survey of proposed NASA missions was undertaken to identify candidate test articles for use in the Middeck Active Control Experiment (MACE). The survey revealed that potential test articles could be classified into one of three roles: development, demonstration, and qualification, depending on the maturity of the technology and the mission the structure must fulfill. A set of criteria was derived that allowed determination of which role a potential test article must fulfill. A review of the capabilities and limitations of the STS middeck was conducted. A reference design for the MACE test article was presented. Computing requirements for running typical closed-loop controllers was determined, and various computer configurations were studied. The various components required to manufacture the structure were identified. A management plan was established for the remainder of the program experiment development, flight and ground systems development, and integration to the carrier. Procedures for configuration control, fiscal control, and safety, reliabilty, and quality assurance were developed.

Crawley, Edward F.↗

NASA NTRS1990

Structural control sensors for CASES

The Remote Attitude Measurement Sensor (RAMS) is currently baselined to meet two important sensor needs for CASES (Control, Astrophysics and Structures Experiment in Space). First, as a tip displacement sensor, RAMS is designed to provide accurate knowledge of the position and orientation of the boom tip assembly. Secondly, as a boom motion tracker, it is designed to monitor 43 reflective targets which are distributed along the length of the boom and provide displacment information for post facto processing. The design and operation of RAMS as these two types of sesnors are described, and attention is given to how RAMS interfaces with the CASES closed-loop control system and how systems identification is accommodated.

Davis, Hugh W.↗

NASA NTRS2004

The Precision Formation Flying Integrated Analysis Tool (PFFIAT)

Several space missions presently in the concept phase (e.g. Stellar Imager, Submillimeter Probe of Evolutionary Cosmic Structure, Terrestrial Planet Finder) plan to use multiple spacecraft flying in precise formation to synthesize unprecedently large aperture optical systems. These architectures present challenges to the attitude and position determination and control system; optical performance is directly coupled to spacecraft pointing with typical control requirements being on the scale of milliarcseconds and nanometers. To investigate control strategies, rejection of environmental disturbances, and sensor and actuator requirements, a capability is needed to model both the dynamical and optical behavior of such a distributed telescope system. This paper describes work ongoing at NASA Goddard Space Flight Center toward the integration of a set of optical analysis tools (Optical System Characterization and Analysis Research software, or OSCAR) with the Formation Flying Test Bed (FFTB). The resulting system is called the Precision Formation Flying Integrated Analysis Tool (PFFIAT), and it provides the capability to simulate closed-loop control of optical systems composed of elements mounted on multiple spacecraft. The attitude and translation spacecraft dynamics are simulated in the FFTB, including effects of the space environment (e.g. solar radiation pressure, differential orbital motion). The resulting optical configuration is then processed by OSCAR to determine an optical image. From this image, wavefront sensing (e.g. phase retrieval) techniques are being developed to derive attitude and position errors. These error signals will be fed back to the spacecraft control systems, completing the control loop. A simple case study is presented to demonstrate the present capabilities of the tool.

Stoneking, Eric↗