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NASA NTRSDate not supplied

Operational Modal Analysis of the Artemis I Dynamic Rollout Test and Wet Dress Rehearsal

NASA has developed an expendable heavy lift launch vehicle capability, the Space Launch System (SLS), to support lunar and deep space exploration. The uncrewed Artemis I was the first flight of this new launch vehicle and tested critical systems for the upcoming crewed Artemis II flight to the moon. Accelerations were recorded at a multitude of locations on Artemis, the Mobile Launcher (ML), and the Crawler Transporter (CT)during the rollout of Artemis I from the Vehicle Assembly Building (VAB) to Launch Pad 39B March 2022 and is referred to as the Artemis I Dynamic Rollout Test (DRT). While Artemis I was at Launch Pad 39B, the Wet Dress Rehearsal (WDR) was performed to demonstrate launch readiness and acceleration measurements were also recorded. Finally, Artemis I rolled back from Launch Pad 39B to the VAB in April 2022, where acceleration measurements were also recorded and is referred to as the rollback portion of DRT. Because the forces during rollout and at the launch pad acting on Artemis I, the ML, and the CT are not directly measurable, Operational Modal Analysis (OMA) techniques, instead of traditional Experimental Modal Analysis (EMA) techniques, were used to identify modal characteristics. The OMA analysis of DRT and WDR directly builds upon the lessons learned from the OMA analysis of an earlier rollout of the ML from the VAB. DRT and WDR dynamic characteristics will be used to support SLS Integrated Modal Test finite element model correlation efforts and Exploration Ground System ML and CT finite element model verification and validation, which are part of the Building Block approach the Space Launch System program has implemented. The dynamic characteristics extracted from DRT as well as the rollout acceleration time histories themselves will be used in the development of generic rollout forcing functions that will provide refined estimates of the Artemis IV rollout forces, which will have the heavier and larger SLS Block 1B launch vehicle and Mobile Launcher 2 (ML-2). This paper briefly describes Artemis I, the ML, and the CT physical characteristics, DRT rollout/rollback and WDR data collection, the challenges in implementing OMA techniques due in part to the CT harmonics, and how these challenges were overcome to obtain the Artemis I DRT configuration and WDR configuration modal characteristics.

Apollo↗

NASA NTRS2021

Operational Modal Analysis of the Space Launch System Mobile Launcher on the Crawler Transporter ISVV-010 Rollout

NASA is developing an expendable heavy lift launch vehicle capability, the Space Launch System, to support lunar and deep space exploration. To support this capability, an updated ground infrastructure is required including modifying an existing Mobile Launcher system. The Mobile Launcher is a very large heavy beam/truss steel structure designed to support the Space Launch System during its buildup and integration in the Vehicle Assembly Building, transportation between the Vehicle Assembly Building and launch pad 39B by the Crawler Transporter, and provides the launch platform at the launch pad. As part of the Verification and Validation of the Mobile Launcher and Crawler Transporter, two rollouts of the Mobile Launcher transported by the Crawler Transporter, Integrated System Verification and Validation (ISVV) 005 and 010, have been performed to demonstrate the Crawler Transporter’s ability to transport the Mobile Launcher. ISVV-005 occurred in September 2018 and ISVV-010 occurred in late June 2019. ISVV-005 and ISVV-010 also provided the opportunity to gather data that can be used identify the Mobile Launcher on the Crawler Transporter rollout modal characteristics and refine the estimates of the Artemis I integrated launch vehicle rollout forcing functions. While the rollout environment has historically produced relatively small launch vehicle structural loads for the Saturn/Apollo and Space Shuttle programs in comparison to launch and ascent loads, these relatively small structural loads are inputs to structural fatigue analyses. The same holds true for the Space Launch System. Because the rollout forces acting on the Mobile Launcher and the Crawler Transporter are not directly measurable, Operational Modal Analysis techniques, instead of traditional Experimental Modal Analysis techniques, provide an empirical means to identify the Mobile Launcher on the Crawler Transporter rollout modal characteristics. The ISVV-010 rollout modal characteristics provide important supplemental modal information, which along with the Mobile Launcher modal test that was performed in June 2019 immediately prior to ISVV-010 rollout, combine to reduce uncertainty in the test correlated Mobile Launcher on the Crawler Transporter finite element model. A well test correlated finite element model will play a key role in the Building Block approach the Space Launch System program has implemented as part of its certification process for the Artemis I flight and in refining the Artemis I rollout forcing functions. At the time of the ISVV-005 rollout in September 2018, the Mobile Launcher was still undergoing construction, and therefore its modal characteristics are not directly comparable to those of the Mobile Launcher during the June 2019 Mobile Launcher modal test and subsequent ISVV-010 rollout. Hence the ISVV-005 rollout modal characteristics will not be looked at in this paper. This paper will briefly describe the Mobile Launcher and Crawler Transporter physical characteristics, ISVV-010 rollout data collection, the challenges in implementing Operational Modal Analysis techniques due in part to the Crawler Transporter harmonics, and how these challenges were overcome to obtain the ISVV-010 Mobile Launcher on the Crawler Transporter rollout modal characteristics.

Apollo↗

NASA NTRSDate not supplied

Operational Modal Analysis of the Space Launch System Mobile Launcher on the Crawler Transporter ISVV-010 Rollout

Apollo↗

NASA NTRS2012

Development and Calibration of a System-Integrated Rotorcraft Finite Element Model for Impact Scenarios

Two full-scale crash tests of an MD-500 helicopter were conducted in 2009 and 2010 at NASA Langley's Landing and Impact Research Facility in support of NASA s Subsonic Rotary Wing Crashworthiness Project. The first crash test was conducted to evaluate the performance of an externally mounted composite deployable energy absorber (DEA) under combined impact conditions. In the second crash test, the energy absorber was removed to establish baseline loads that are regarded as severe but survivable. The presence of this energy absorbing device reduced the peak impact acceleration levels by a factor of three. Accelerations and kinematic data collected from the crash tests were compared to a system-integrated finite element model of the test article developed in parallel with the test program. In preparation for the full-scale crash test, a series of sub-scale and MD-500 mass simulator tests were conducted to evaluate the impact performances of various components and subsystems, including new crush tubes and the DEA blocks. Parameters defined for the system-integrated finite element model were determined from these tests. Results from 19 accelerometers placed throughout the airframe were compared to finite element model responses. The model developed for the purposes of predicting acceleration responses from the first crash test was inadequate when evaluating more severe conditions seen in the second crash test. A newly developed model calibration approach that includes uncertainty estimation, parameter sensitivity, impact shape orthogonality, and numerical optimization was used to calibrate model results for the full-scale crash test without the DEA. This combination of heuristic and quantitative methods identified modeling deficiencies, evaluated parameter importance, and proposed required model changes. The multidimensional calibration techniques presented here are particularly effective in identifying model adequacy. Acceleration results for the calibrated model were compared to test results and the original model results. There was a noticeable improvement in the pilot and copilot region, a slight improvement in the occupant model response, and an over-stiffening effect in the passenger region. One lesson learned was that this approach should be adopted early on, in combination with the building-block approaches that are customarily used, for model development and pretest predictions. Complete crash simulations with validated finite element models can be used to satisfy crash certification requirements, potentially reducing overall development costs.

Annett, Martin S.↗

NASA NTRS2012

Calibration of Airframe and Occupant Models for Two Full-Scale Rotorcraft Crash Tests

Two full-scale crash tests of an MD-500 helicopter were conducted in 2009 and 2010 at NASA Langley's Landing and Impact Research Facility in support of NASA s Subsonic Rotary Wing Crashworthiness Project. The first crash test was conducted to evaluate the performance of an externally mounted composite deployable energy absorber under combined impact conditions. In the second crash test, the energy absorber was removed to establish baseline loads that are regarded as severe but survivable. Accelerations and kinematic data collected from the crash tests were compared to a system integrated finite element model of the test article. Results from 19 accelerometers placed throughout the airframe were compared to finite element model responses. The model developed for the purposes of predicting acceleration responses from the first crash test was inadequate when evaluating more severe conditions seen in the second crash test. A newly developed model calibration approach that includes uncertainty estimation, parameter sensitivity, impact shape orthogonality, and numerical optimization was used to calibrate model results for the second full-scale crash test. This combination of heuristic and quantitative methods was used to identify modeling deficiencies, evaluate parameter importance, and propose required model changes. It is shown that the multi-dimensional calibration techniques presented here are particularly effective in identifying model adequacy. Acceleration results for the calibrated model were compared to test results and the original model results. There was a noticeable improvement in the pilot and co-pilot region, a slight improvement in the occupant model response, and an over-stiffening effect in the passenger region. This approach should be adopted early on, in combination with the building-block approaches that are customarily used, for model development and test planning guidance. Complete crash simulations with validated finite element models can be used to satisfy crash certification requirements, thereby reducing overall development costs.

Annett, Martin S.↗

NASA NTRS2023

Effect of Loading Rate on the Open Hole Compression Strength of Quasi-Isotropic Carbon/Epoxy Laminates

This study was undertaken to examine how well the 0.05 inch/min loading rate typically used to develop allowables for open hole compression strength of carbon/epoxy laminates represents structures that may experience a much lower loading rate (such as civil engineering structures) or a much higher loading rate (such as a rocket interstage at liftoff). The Composite Materials Handbook-17 (CMH-17) suggests developing strength allowables at the coupon level (lowest level of the “building block” approach) and using a rigorous statistical analysis to arrive at a strength allowable upon which the structure is to be further designed at higher levels of the building block pyramid. But do these coupon level tests truly represent meaningful stresses at which the composite in the final structure can withstand considering the effects of loading rate? Open hole compression (OHC) strength was chosen for this study since most structures are designed to some damage tolerance criteria and OHC strength testing is rather simple to perform. A quasi-isotropic lay-up was chosen since this is a very common lay-up sequence. The results show that for structures that experience a very small loading rate (0.0005 in/min) the allowables developed at the standard 0.05 in/min loading rate are higher than what the composite can withstand at this lower loading rate. Conversely, at a high loading rate of 10 in/min the strength values found at the standard test rate of 0.05 in/min are slightly lower and not “in family” using the statistics suggested in CMH-17. These results question if standardized test rates are reliable, at least to the fidelity of being “in family” per CMH-17. Some creep rupture tests were also performed to demonstrate that OHC strength values could be lower than the slowest test speed used in this study (0.0005 in/min).

open hole compression strength↗

NASA NTRS1994

Renaissance architecture for Ground Data Systems

The Mission Operations and Data Systems Directorate (MO&DSD) has embarked on a new approach for developing and operating Ground Data Systems (GDS) for flight mission support. This approach is driven by the goals of minimizing cost and maximizing customer satisfaction. Achievement of these goals is realized through the use of a standard set of capabilities which can be modified to meet specific user needs. This approach, which is called the Renaissance architecture, stresses the engineering of integrated systems, based upon workstation/local area network (LAN)/fileserver technology and reusable hardware and software components called 'building blocks.' These building blocks are integrated with mission specific capabilities to build the GDS for each individual mission. The building block approach is key to the reduction of development costs and schedules. Also, the Renaissance approach allows the integration of GDS functions that were previously provided via separate multi-mission facilities. With the Renaissance architecture, the GDS can be developed by the MO&DSD or all, or part, of the GDS can be operated by the user at their facility. Flexibility in operation configuration allows both selection of a cost-effective operations approach and the capability for customizing operations to user needs. Thus the focus of the MO&DSD is shifted from operating systems that we have built to building systems and, optionally, operations as separate services. Renaissance is actually a continuous process. Both the building blocks and the system architecture will evolve as user needs and technology change. Providing GDS on a per user basis enables this continuous refinement of the development process and product and allows the MO&DSD to remain a customer-focused organization. This paper will present the activities and results of the MO&DSD initial efforts toward the establishment of the Renaissance approach for the development of GDS, with a particular focus on both the technical and process implications posed by Renaissance to the MO&DSD.

Perkins, Dorothy C.↗

NASA NTRSDate not supplied

Thermoplastic Composite Lunar Tower Truss Structure: Design Development and Verification Plans

The National Aeronautics and Space Administration (NASA) Space Technology and Mission Directorate (STMD) is advancing thermoplastic composite (TPC) technologies for exploration missions. The Technology Development for Exploration Applications (TDEA) project goals are to develop and mature TPC materials, designs, analyses tools and techniques, and mature manufacturing processes. This includes development of manufacturing and joining approaches relevant to space environments. To these ends TDEA endeavors toward demonstrating a TPC truss structure for a lunar tower configuration. The design, predicated on robotic assembly, uses open section truss elements fused to a joint splice plate, without a structural adhesive. This presentation details the TDEA lunar truss structure design development approach including design heritage, the requirements established, the mechanical design and analyses, and thermal analyses demonstrating structural requirements conformance, as well as planned building block verification efforts either underway or planned. The mechanical analyses show the most severe environment is a moon-quake the truss dynamic responses. The thermal analyses show the extreme cold for on-orbit welding, the window for less severe on-orbit welding, as well as the large thermal gradients on the truss. The building block approach shown includes ultrasonic welding and lap shear coupon testing on various truss element thicknesses and layups. Knockdown factor determinations due to lunar dust contamination (simulated) and effects of welding in a vacuum are presented. The most highly loaded truss joint configuration sub-element verification test matrix is outlined. Lastly, plans to build, inspect, and test a 2-bay truss representative unit cell that is 1.5 meters by 1.5 meters by 3.0 meters tall are detailed.

Lunar Tower↗

NASA NTRS1991

Observations on practical turbulence modeling for high-speed jet/plume flowfields

An overview is presented of the current status in terms of simulating basic high-speed/straightback free jet flowfields with two-equation turbulence models. A building-block approach is described which provides a systematic method of calibrating such turbulence models. Data to support this approach focuses on obtaining turbulence modeling capabilities to reproduce basic mean flow structure for simple flows before progressing to more complex problems. For transverse jets and wall jets, new building-blocks of data are necessary with turbulence modeling capabilities unifying the free jet building-blocks discussed, and fundamental boundary layer and shock/boundary layer interaction building-blocks resulting from other studies.

Dash, Sanford M.↗

NASA NTRS1994

SCOS 2: ESA's new generation of mission control system

New mission-control infrastructure is currently being developed by ESOC, which will constitute the second generation of the Spacecraft Control Operations system (SCOS 2). The financial, functional and strategic requirements lying behind the new development are explained. The SCOS 2 approach is described. The technological implications of these approaches is described: in particular it is explained how this leads to the use of object oriented techniques to provide the required 'building block' approach. The paper summarizes the way in which the financial, functional and strategic requirements have been met through this combination of solutions. Finally, the paper outlines the development process to date, noting how risk reduction was achieved in the approach to new technologies and summarizes the current status future plans.

Jones, M.↗

NASA NTRS1990

Integrated space transportation evolution

The development of an evolutionary approach to a space transportation system to meet the needs of the Space Exploration Initiative and other earth orbital and planetary missions is discussed. Common architectures, a building block approach to space transportation elements, the development of alternative technologies are considered as essential steps to arriving at an integrated space transportation system. These aspects are addressed as they apply to both lunar and Mars technology.

Huffaker, Frederick↗

NASA NTRS1994

Impact force as a scaling parameter

The Federal Aviation Administration (FAR PART 25) requires that a structure carry ultimate load with nonvisible impact damage and carry 70 percent of limit flight loads with discrete damage. The Air Force has similar criteria (MIL-STD-1530A). Both civilian and military structures are designed by a building block approach. First, critical areas of the structure are determined, and potential failure modes are identified. Then, a series of representative specimens are tested that will fail in those modes. The series begins with tests of simple coupons, progresses through larger and more complex subcomponents, and ends with a test on a full-scale component, hence the term 'building block.' In order to minimize testing, analytical models are needed to scale impact damage and residual strength from the simple coupons to the full-scale component. Using experiments and analysis, the present paper illustrates that impact damage can be better understood and scaled using impact force than just kinetic energy. The plate parameters considered are size and thickness, boundary conditions, and material, and the impact parameters are mass, shape, and velocity.

Poe, Clarence C., Jr.↗

NASA NTRS1984

Analytical Models

A system-level design and analysis model was developed. This model was conceived to have several key elements: a solar pond thermodynamic performance model, a power generation subsystem model, and an economic analysis element. The basic approach was to create these elements or modules and refine them on an individual basis yet retain the capability to easily couple them into a full system design model. This building block approach allows for maximum flexibility and substitution of refined descriptions as the technology develops. A general overview of interconnecting these subsystem models is presented. The primary program control element will perform the administrative functions of data input, data output, information storage and transfer, and sequential calling of the subsystem models. From the point of view of the requirements of a system design model, a power conversion subsystem model was developed. The goal of the effort was a preliminary subsystem model compatible with the solar pond subsystem model so that a first order system simulation analysis could be performed.

Source record↗

NASA NTRSDate not supplied

Strategy for Developing Technologies for Megawatt-class Nuclear Electric Propulsion Systems

A strategy for maturing the technologies required for a megawatt-class nuclear electric propulsion (NEP) system is presented. The effort is responsive to recent non-advocate reviews stating high-power NEP technologies were relatively immature and significant maturation was required before contemplating the use of NEP on a flight mission. The maturation strategy presented accomplishes this through hardware test and evaluation at the sizes, scales, and conditions expected during high-power NEP missions. The development effort is accompanied by modeling of such a system to demonstrate thorough understanding and verification of the performance, lifetime, and failure modes. The proposed effort uses a building-block approach, maturing technologies for a 1 MWe block under the assumption that a future high-power NEP mission will have requirements that can be met either through straightforward scaling of this building block to the levels required or through the use of multiple blocks to meet the overall power needs. The plan is outlined for maturation to technology readiness level 5, characterized by test and evaluation using brassboard-fidelity hardware in a relevant environment and by demonstration of agreement between test data and analytical predictions.

Kurt A. Polzin↗

NASA NTRS2009

Technology Challenges and Opportunities for Very Large In-Space Structural Systems

Space solar power satellites and other large space systems will require creative and innovative concepts in order to achieve economically viable designs. The mass and volume constraints of current and planned launch vehicles necessitate highly efficient structural systems be developed. In addition, modularity and in-space deployment/construction will be enabling design attributes. While current space systems allocate nearly 20 percent of the mass to the primary structure, the very large space systems of the future must overcome subsystem mass allocations by achieving a level of functional integration not yet realized. A proposed building block approach with two phases is presented to achieve near-term solar power satellite risk reduction with accompanying long-term technology advances. This paper reviews the current challenges of launching and building very large space systems from a structures and materials perspective utilizing recent experience. Promising technology advances anticipated in the coming decades in modularity, material systems, structural concepts, and in-space operations are presented. It is shown that, together, the current challenges and future advances in very large in-space structural systems may provide the technology pull/push necessary to make solar power satellite systems more technically and economically feasible.

Belvin, W. Keith↗

NASA NTRSDate not supplied

The Gateway as a Building Block for Space Exploration and Development

The Gateway, which will be a small, human-tended space station in orbit around the Moon, is an example of the building block approach to space exploration and development. The National Aeronautics and Space Administration (NASA) leads the Gateway Program and serves as the integrator of the spaceflight capabilities and contributions of U.S. commercial partners and international partners. Gateway is a cornerstone of deep space human exploration, one critical element of the strategies and architectures that will enable human exploration of the solar system. This paper will outline: 1) The concept of operations and describe how Gateway is a multipurpose space station, supporting lunar surface missions, cis-lunar research, and as a proving ground for human missions to Mars; 2) Gateway’s international partnerships as an expansion of the partnerships of the “second generation of space programmes,” namely the International Space Station (ISS); and 3) Future commercial, scientific, and technology demonstration opportunities that this infrastructure building block provides. Lastly, the strategies and architectures for future space exploration and development must include thoughtful approaches to the management and business operations of government space programs. This includes planning for limited outyear growth in budgets, partnership and acquisition strategies, pursuing public-private partnerships and the use of firm-fixed price contracts, enabling vendor-to-vendor relationships, the use of multilateral interoperability standards, and incorporating key lessons learned from prior governmental Programs. This paper will discuss the strategies and approaches undertaken when establishing the Gateway Program at the NASA Johnson Space Center in 2019 and the current operational status of this new, lean, and efficient Program.

Gateway↗

NASA NTRSDate not supplied

The Gateway as a Building Block for Space Exploration and Development

The Gateway, which will be a small, human-tended space station in orbit around the Moon, is an example of the building block approach to space exploration and development. The National Aeronautics and Space Administration (NASA) leads the Gateway Program and serves as the integrator of the spaceflight capabilities and contributions of U.S. commercial partners and international partners. Gateway is a cornerstone of deep space human exploration, one critical element of the strategies and architectures that will enable human exploration of the solar system. This paper will outline: 1) The concept of operations and describe how Gateway is a multi-purpose space station, supporting lunar surface missions, cis-lunar research, and as a proving ground for human missions to Mars; 2) Gateway’s international partnerships as an expansion of the partnerships of the “second generation of space programmes,” namely the International Space Station (ISS); and 3) Future commercial, scientific, and technology demonstration opportunities that this infrastructure building block provides. Lastly, the strategies and architectures for future space exploration and development must include thoughtful approaches to the management and business operations of government space programs. This includes planning for limited outyear growth in budgets, partnership and acquisition strategies, pursuing public-private partnerships and the use of firm-fixed price contracts, enabling vendor-to-vendor relationships, the use of multilateral interoperability standards, and incorporating key lessons learned from prior governmental Programs. This paper will discuss the strategies and approaches undertaken when establishing the Gateway Program at the NASA Johnson Space Center in 2019 and the current operational status of this new, lean, and efficient Program.

Gateway↗

NASA NTRS1977

Large space erectable structures - building block structures study

A modular planar truss structure and a long slender boom concept identified as building block approaches to construction of large spacecraft configurations are described. The concepts are compatible in weight and volume goals with the Space Transportation System, use standard structural units, and represent high on-orbit productivity in terms of structural area or beam length. Results of structural trade studies involving static and dynamic analyses of a single module and rigid body deployment analyses to assess kinetics and kinematics of automatic deployment of the building block modules are presented.

Armstrong, W. H.↗