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Design and operations technologies - Integrating the pieces

As major elements of life-cycle costs (LCC) having critical impacts on the initiation and utilization of future space programs, the areas of vehicle design and operations are reviewed in order to identify technology requirements. Common to both areas is the requirement for efficient integration of broad, complex systems. Operations technologies focus on the extension of space-based capabilities and cost reduction through the combination of innovative design, low-maintenance hardware, and increased manpower productivity. Design technologies focus on computer-aided techniques which increase productivity while maintaining a high degree of flexibility which enhances creativity and permits graceful design changes.

Eldred, C. H.↗

The Fuel Cell Powered Club Car Carryall

The NASA Glenn Research Center initiated development of the Fuel Cell Powered Club Car Carryall as a way to reduce pollution in industrial settings, reduce fossil fuel consumption and reduce operating costs for transportation systems. The Club Car Carryall provides an inexpensive approach to advance the state of the art in electric vehicle technology in a practical application. The project transfers space technology to terrestrial use via non-traditional partners, and provides power system data valuable for future aeronautics and space applications. The work was done under the Hybrid Power Management (HPM) Program. The Carryall is a state of the art, dedicated, electric utility vehicle. Hydrogen powered proton exchange membrane (PEM) fuel cells are the primary power source. Ultracapacitors were used for energy storage as long life, maintenance free operation, and excellent low temperature performance is essential. Metal hydride hydrogen storage was used to store hydrogen in a safe and efficient low-pressure solid form. The report concludes that the Fuel Cell Powered Club Car Carryall can provide excellent performance, and that the implementation of fuel cells in conjunction with ultracapacitors in the power system can provide significant reliability and performance improvements.

Eichenberg, Dennis J.↗

NASA Centennial Challenges Deep Space Food Challenge Competition to Incentivize Innovation in Food Systems for Long-Duration Space Exploration Missions

The Centennial Challenges (CC) program, currently part of NASA’s Space Technology Mission Directorate (STMD), is one of the vehicles NASA uses to develop and execute public prize competitions. Since opening its first challenge in 2005, the CC program has initiated more than 20 challenges in a variety of technology areas. This paper provides the background, development and execution of the Deep Space Food Challenge as one approach to fulfilling NASA’s Space Policy Directive 1 (“To the Moon, then Mars”). Specifics about the CC program’s accomplishments will also be discussed. The Deep Space Food Challenge (DSF) was developed in collaboration with the Canadian Space Agency (CSA) to create novel food production technologies with minimal inputs, and maximum safe, nutritious, palatable food outputs for long-duration space missions, which have potential to benefit people on Earth. When humans return to the lunar surface in the mid-2020s, the early missions will use prepackaged foods similar to those in use on the International Space Station (ISS) today. However, extending the duration of lunar missions requires reducing resupply dependency on Earth. Testing a sustainable system on the Moon that meets lunar crews’ needs is a fundamental step for lunar sustainability and future Mars exploration. NASA and CSA are focused on how to furnish crew members with a viable food system for long duration space missions that provides all daily nutritional needs through a variety of palatable, safe food with limited resource requirements and no dependency on resupply from Earth; and enables acceptable, safe and quick preparation methods. On Earth, technology solutions for food systems could also be used to produce nutritional sources for urban and rural environments; potentially leading to a reduced impact on our Earth’s resources. Challenges, such as the DSF, are an embodiment of NASA’s continuing commitment to technological advancement and innovation through non-traditional programs.

Centennial Challenges↗

Extended mission life support systems

Extended manned space missions which include interplanetary missions require regenerative life support systems. Manned mission life support considerations are placed in perspective and previous manned space life support system technology, activities and accomplishments in current supporting research and technology (SR&T) programs are reviewed. The life support subsystem/system technologies required for an enhanced duration orbiter (EDO) and a space operations center (SOC), regenerative life support functions and technology required for manned interplanetary flight vehicles, and future development requirements are outlined. The Space Shuttle Orbiters (space transportation system) is space cabin atmosphere is maintained at Earth ambient pressure of 14.7 psia (20% O2 and 80% N2). The early Shuttle flights will be seven-day flights, and the life support system flight hardware will still utilize expendables.

Quattrone, P. D.↗

OAST Technology for the Future. Volume 3 - Critical Technologies, Themes 5-8

NASA's Office of Aeronautics and Space Technology (OAST) conducted a workshop on the In-Space Technology Experiments Program IN-STEP) December 6-9, 1988, in Atlanta, Georgia. The purpose of this workshop was to identify and prioritize space technologies which are critical for future national space programs and which require validation in the 5 ace environment. A secondary objective was to review the current NASA (In-Reach and Industry/University (Out-Reach) experiments. Finally, the aerospace community was requested to review and comment on the proposed plans for the continuation of the In-Space Technology Experiments Program. In particular, the review included the proposed process for focusing the next experiment selection on specific, critical technologies and the process for implementing the hardware development and integration on the Space Shuttle vehicle. The product of the workshop was a prioritized listing of the critical space technology needs in each of eight technology disciplines. These listings were the cumulative recommendations of nearly 400 participants, which included researchers, technologists, and managers from aerospace industries, universities, and government organizations.

U2607↗

OAST Technology for the Future. Volume 2 - Critical Technologies, Themes 1-4

NASA's Office of Aeronautics and Space Technology (OAST) conducted a workshop on the In-Space Technology Experiments Program IN-STEP) December 6-9, 1988, in Atlanta, Georgia. The purpose of this workshop was to identify and prioritize space technologies which are critical for future national space programs and which. require validation in the space environment. A secondary objective was to review the current NASA (InReach) and Industry/University (Out-Reach) experiments. Finally, the aerospace community was requested to review and comment on the proposed plans for the continuation of the In-Space Technology Experiments Program. In particular, the review included the proposed process for focusing the next experiment selection on specific, critical technologies and the process for implementing the hardware development and integration on the Space Shuttle vehicle. The product of the workshop was a prioritized listing of the critical space technology needs in each of eight technology disciplines. These listings were the cumulative recommendations of nearly 400 participants, which included researchers, technologists, and managers from aerospace industries, universities, and government organizations.

OAST (AERONAUTICS AND SPACE TECHNOLOGY)↗

OAST Technology for the Future. Executive Summary

NASA's Office of Aeronautics and Space Technology (OAST) conducted a workshop on the In-Space Technology Experiments Program (IN-STEP) December 6-9, 1988, in Atlanta, Georgia. The purpose of this workshop was to identify and prioritize space technologies which are critical for future national space programs and which require validation in the space environment. A secondary objective was to review the current NASA (In-Reach) and Industry/University (Out-Reach) experiments. Finally, the aerospace community was requested to review and comment on the proposed plans for the continuation of the In-Space Technology Experiments Program. In particular, the review included the proposed process for focusing the next experiment selection on specific, critical technologies and the process for implementing the hardware development and integration on the Space Shuttle vehicle. The product of the workshop was a prioritized listing of the critical space technology needs in each of eight technology disciplines. These listings were the cumulative recommendations of nearly 400 participants, which included researchers, technologists, and managers from aerospace industries, universities, and government organizations.

BMDO COLLECTION↗

A study of the compatibility of science instruments with the solar electric propulsion space vehicle

Electromagnetic interference and field-of-view constraints are identified as the areas of most concern to science on solar electric propulsion space vehicles. Several areas are indicated which more detailed data on the space vehicle environment are needed. In addition, possible means to attain or demonstrate science/space vehicle compatibility are recommended for further iteration between space vehicle design and science payload considerations. The space vehicle design developed by the solar electric propulsion system integration technology effort is used. Two payload sets for comet Encke missions (a slow flyby and a rendezvous), as well as several instruments which are not included in the two payload sets, are analyzed to determine requirements on the space vehicle imposed by the instruments in order to meet their objectives. Environmental requirements for the sets of instruments are developed and compared to both the SEPSIT design criteria and the environment as it is presently understood.

Parker, R. H.↗

Seal Technology for Hypersonic Vehicle and Propulsion: An Overview

Hypersonic vehicles and propulsion systems pose an extraordinary challenge for structures and materials. Airframes and engines require lightweight, high-temperature materials and structural configurations that can withstand the extreme environment of hypersonic flight. Some of the challenges posed include very high temperatures, heating of the whole vehicle, steady-state and transient localized heating from shock waves, high aerodynamic loads, high fluctuating pressure loads, potential for severe flutter, vibration, and acoustic loads and erosion. Correspondingly high temperature seals are required to meet these aggressive requirements. This presentation reviews relevant seal technology for both heritage (e.g. Space Shuttle, X-15, and X-38) vehicles and presents several seal case studies aimed at providing lessons learned for future hypersonic vehicle seal development. This presentation also reviews seal technology developed for the National Aerospace Plane propulsion systems and presents several seal case studies aimed at providing lessons learned for future hypersonic propulsion seal development.

Steinetz, Bruce M.↗

NASA/MOD Operations Impacts from Shuttle Program

Operations plays a pivotal role in the success of any human spaceflight program. This paper will highlight some of the core tenets of spaceflight operations from a systems perspective and use several examples from the Space Shuttle Program to highlight where the success and safety of a mission can hinge upon the preparedness and competency of the operations team. Further, awareness of the types of operations scenarios and impacts that can arise during human crewed space missions can help inform design and mission planning decisions long before a vehicle gets into orbit. A strong operations team is crucial to the development of future programs; capturing the lessons learned from the successes and failures of a past program will allow for safer, more efficient, and better designed programs in the future. No matter how well a vehicle is designed and constructed, there are always unexpected events or failures that occur during space flight missions. Preparation, training, real-time execution, and troubleshooting are skills and values of the Mission Operations Directorate (MOD) flight controller; these operational standards have proven invaluable to the Space Shuttle Program. Understanding and mastery of these same skills will be required of any operations team as technology advances and new vehicles are developed. This paper will focus on individual Space Shuttle mission case studies where specific operational skills, techniques, and preparedness allowed for mission safety and success. It will detail the events leading up to the scenario or failure, how the operations team identified and dealt with the failure and its downstream impacts. The various options for real-time troubleshooting will be discussed along with the operations team final recommendation, execution, and outcome. Finally, the lessons learned will be summarized along with an explanation of how these lessons were used to improve the operational preparedness of future flight control teams.

Fitzpatrick, Michael↗

Wavefront Analysis of Adaptive Telescope

The motivation for this work came from a NASA Headquarters interest in investigating design concepts for a large space telescope employing active optics technology. Current and foreseeable launch vehicles will be limited to carrying around 4-5 meter diameter objects. Thus, if a large, filled-aperture telescope (6-20 meters in diameter) is to be placed in space, it will be required to have a deployable primary mirror. Such a mirror may be an inflatable membrane or a segmented mirror consisting of many smaller pieces. In any case, it is expected that the deployed primary will not be of sufficient quality to achieve diffraction-limited performance for its aperture size. Thus, an active optics system will be needed to correct for initial as well as environmentally-produced primary figure errors. Marshall Space Flight Center has developed considerable expertise in the area of active optics with the PAMELA test-bed. The combination of this experience along with the Marshall optical shop's work in mirror fabrication made MSFC the logical choice to lead NASA's effort to develop active optics technology for large, space-based, astronomical telescopes. Furthermore, UAH's support of MSFC in the areas of optical design, fabrication, and testing of space-based optical systems placed us in a key position to play a major role in the development of this future-generation telescope. A careful study of the active optics components had to be carried out in order to determine control segment size, segment quality, and segment controllability required to achieve diffraction-limited resolution with a given primary mirror. With this in mind, UAH undertook the following effort to provide NASA/MSFC with optical design and analysis support for the large telescope study. All of the work performed under this contract has already been reported, as a team member with MSFC, to NASA Headquarters in a series of presentations given between May and December of 1995. As specified on the delivery order, this report simply summarizes the material with the various UAH-written presentation packages attached as appendices.

Hadaway, James B.↗

Waste Collector System Technology Comparisons for Constellation Applications

The Waste Collection Systems (WCS) for space vehicles have utilized a variety of hardware for collecting human metabolic wastes. It has typically required multiple missions to resolve crew usability and hardware performance issues that are difficult to duplicate on the ground. New space vehicles should leverage off past WCS systems. Past WCS hardware designs are substantially different and unique for each vehicle. However, each WCS can be analyzed and compared as a subset of technologies which encompass fecal collection, urine collection, air systems, pretreatment systems. Technology components from the WCS of various vehicles can then be combined to reduce hardware mass and volume while maximizing use of previous technology and proven human-equipment interfaces. Analysis of past US and Russian WCS are compared and extrapolated to Constellation missions.

Broyan, James Lee, Jr.↗

NASA Glenn Research Center's Hypersonic Propulsion Program

NASA Glenn Research Center (GRC), as NASA's lead center for aeropropulsion, is responding to the challenge of reducing the cost of space transportation through the integration of air-breathing propulsion into launch vehicles. Air- breathing launch vehicle (ABLV) propulsion requires a marked departure from traditional propulsion applications. and stretches the technology of both rocket and air-breathing propulsion. In addition, the demands of the space launch mission require an unprecedented level of integration of propulsion and vehicle systems. GRC is responding with a program with rocket-based combined cycle (RBCC) propulsion technology as its main focus. RBCC offers the potential for simplicity, robustness, and performance that may enable low-cost single-stage-to-orbit (SSTO) transportation. Other technologies, notably turbine-based combined cycle (TBCC) propulsion, offer benefits such as increased robustness and greater mission flexibility, and are being advanced, at a slower pace, as part of GRC's program in hypersonics.

Palac, Donald T.↗

Advanced Energy Conversion Technologies and Architectures for Earth and Beyond

Research, development and studies of novel space-based solar power systems, technologies and architectures for Earth and beyond are needed to reduce the cost of clean electrical power for terrestrial use and to provide a stepping stone for providing an abundance of power in space, i.e., manufacturing facilities, tourist facilities, delivery of power between objects in space, and between space and surface sites. The architectures, technologies and systems needed for space to Earth applications may also be used for in-space applications. Advances in key technologies, i.e., power generation, power management and distribution, power beaming and conversion of beamed power are needed to achieve the objectives of both terrestrial and extraterrestrial applications. There is a need to produce "proof-ofconcept" validation of critical WPT technologies for both the near-term, as well as far-term applications. Investments may be harvested in near-term beam safe demonstrations of commercial WPT applications. Receiving sites (users) include ground-based stations for terrestrial electrical power, orbital sites to provide power for satellites and other platforms, future space elevator systems, space vehicle propulsion, and space surface sites. Space surface receiving sites of particular interest include the areas of permanent shadow near the moon s North and South poles, where WPT technologies could enable access to ice and other useful resources for human exploration. This paper discusses work addressing a promising approach to solar power generation and beamed power conversion. The approach is based on a unique high-power solar concentrator array called Stretched Lens Array (SLA) applied to both solar power generation and beamed power conversion. Since both versions (solar and laser) of SLA use many identical components (only the photovoltaic cells need to be different), economies of manufacturing and scale may be realized by using SLA on both ends of the laser power beaming system in a space solar power application. Near-term uses of this SLA-laser-SLA system may include terrestrial and space exploration in near Earth space. Later uses may include beamed power for bases or vehicles on Mars. Strategies for developing energy infrastructures in space which utilize this technology are presented. This dual use system produces electrical energy efficiently from either coherent light, such as from a highly coherent laser, or from conventional solar illumination. This allows, for example, supplementing solar energy with energy provided by highly coherent laser illumination during periods of low solar illumination or no illumination. This reduces the need for batteries and alternate sources of power. The capability of using laser illumination in a lowest order Gaussian laser mode provides means for transmitting power optically with maximum efficiency and precision over the long distances characteristic of space. A preliminary receiving system similar to that described here, has been produced and tested under solar and laser illumination. A summary of results is given.

Howell, Joe T.↗

ADVANCED VALVE TECHNOLOGY FOR SPACECRAFT ENGINES FINAL REPORT

This final report describes the work that was done to determine the state-of-the-art of valves required for space exploration vehicles and the steps that were taken to advance the technology. Interviews were held with personnel of major prime manufacturers to determine current problems and current and future requirements. Manufacturers were surveyed by mail to determine what equipment is presently being produced. An extensive search of patent office files was made to determine if any novel valve concepts not already applied to aerospace valves might exist. A literature search was conducted to provide the necessary technical information that was required for the program. Several extensive studies were made to determine the effects on materials resulting from use in space applications, and an investigation of the basic phenomena of valve seat wear was initiated. With the information developed in the surveys and studies, the significant problems associated with valves were identified and are described under "Discussion of Problems. " A novel valve concept was developed and a prototype valve was built and successfully tested. A seal compound of Teflon and stainless steel was developed which possesses superior cold flow characteristics while retaining the desirable properties of the basic Teflon material.

Spacecraft propulsion↗

Space reliability technology - A historical perspective

The progressive improvements in reliability of launch vehicles is traced from the Vanguard rocket to the STS. The Vanguard, built with minimal redundancy and a high mass ratio, was used as an operational vehicle midway through its test program in an attempt to meet the perceived challenge represented by the Sputnik. The fourth Vanguard failed due to inadequate contamination prevention and lack of inspection ports. Automatic firing sequences were adopted for the Titan rockets, which were an order of magnitude larger than the Vanguard and therefore had room for interior inspections. Qualification testing and reporting were introduced for components, along with X ray inspection of fuel tank welds. Dual systems were added for flight critical components when the Titan became man-rated for the Gemini program. Designs incorporated full failure mode effects and criticality analyses for the Apollo program, which exposed the limits of applicability of numerical reliability models. Fault tree analyses and program milestone reviews were initiated. The worth of man-in-the-loop in space activities for reliability was demonstrated with the rescue of Skylab after solar panel and meteoroid shield failures. It is now the reliability of the payload, rather than the vehicle, that is questioned for Shuttle launches.

Cohen, H.↗

In-Space Structural Assembly: Applications and Technology

As NASA exploration moves beyond earth's orbit, the need exists for long duration space systems that are resilient to events that compromise safety and performance. Fortunately, technology advances in autonomy, robotic manipulators, and modular plug-and-play architectures over the past two decades have made in-space vehicle assembly and servicing possible at acceptable cost and risk. This study evaluates future space systems needed to support scientific observatories and human/robotic Mars exploration to assess key structural design considerations. The impact of in-space assembly is discussed to identify gaps in structural technology and opportunities for new vehicle designs to support NASA's future long duration missions.

Belvin, W. Keith↗

Emerging Needs for Pervasive Passive Wireless Sensor Networks on Aerospace Vehicles

NASA is investigating passive wireless sensor technology to reduce instrumentation mass and volume in ground testing, air flight, and space exploration applications. Vehicle health monitoring systems (VHMS) are desired on all aerospace programs to ensure the safety of the crew and the vehicles. Pervasive passive wireless sensor networks facilitate VHMS on aerospace vehicles. Future wireless sensor networks on board aerospace vehicles will be heterogeneous and will require active and passive network systems. Since much has been published on active wireless sensor networks, this work will focus on the need for passive wireless sensor networks on aerospace vehicles. Several passive wireless technologies such as microelectromechanical systems MEMS, SAW, backscatter, and chipless RFID techniques, have all shown potential to meet the pervasive sensing needs for aerospace VHMS applications. A SAW VHMS application will be presented. In addition, application areas including ground testing, hypersonic aircraft and spacecraft will be explored along with some of the harsh environments found in aerospace applications.

Wilson, William C.↗