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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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29 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1992

The ROMPS robot in HitchHiker

The Robotics Branch of the Goddard Space Flight Center has under development a robot that fits inside a Get Away Special can. In the RObotic Materials Processing System (ROMPS) HitchHiker experiment, this robot is used to transport pallets containing wafers of different materials from their storage rack to a halogen lamp furnace for rapid thermal processing in a microgravity environment. It then returns them to their storage rack. A large part of the mechanical design of the robot dealt with the potential misalignment between the various components that are repeatedly mated and demated. A system of tapered guides and compliant springs was designed to work within the robot's force and accuracy capabilities. This paper discusses the above and other robot design issues in detail, and presents examples of ROMPS robot analyses that are applicable to other HitcherHiker materials handling missions.

Voellmer, George↗
NASA NTRS1998

Comparison Of Human Modelling Tools For Efficiency Of Prediction Of EVA Tasks

Construction of the International Space Station (ISS) will require extensive extravehicular activity (EVA, spacewalks), and estimates of the actual time needed continue to rise. As recently as September, 1996, the amount of time to be spent in EVA was believed to be about 400 hours, excluding spacewalks on the Russian segment. This estimate has recently risen to over 1100 hours, and it could go higher before assembly begins in the summer of 1998. These activities are extremely expensive and hazardous, so any design tools which help assure mission success and improve the efficiency of the astronaut in task completion can pay off in reduced design and EVA costs and increased astronaut safety. The tasks which astronauts can accomplish in EVA are limited by spacesuit mobility. They are therefore relatively simple, from an ergonomic standpoint, requiring gross movements rather than time motor skills. The actual tasks include driving bolts, mating and demating electric and fluid connectors, and actuating levers; the important characteristics to be considered in design improvement include the ability of the astronaut to see and reach the item to be manipulated and the clearance required to accomplish the manipulation. This makes the tasks amenable to simulation in a Computer-Assisted Design (CAD) environment. For EVA, the spacesuited astronaut must have his or her feet attached on a work platform called a foot restraint to obtain a purchase against which work forces may be actuated. An important component of the design is therefore the proper placement of foot restraints.

Dischinger, H. Charles, Jr.↗
NASA NTRS1997

Evaluation of a Human Modeling Software Tool in the Prediction of Extra Vehicular Activity Tasks for an International Space Station Assembly Mission

The difficulty of accomplishing work in extravehicular activity (EVA) is well documented. It arises as a result of motion constraints imposed by a pressurized spacesuit in a near-vacuum and of the frictionless environment induced in microgravity. The appropriate placement of foot restraints is crucial to ensuring that astronauts can remove and drive bolts, mate and demate connectors, and actuate levers. The location on structural members of the foot restraint sockets, to which the portable foot restraint is attached, must provide for an orientation of the restraint that affords the astronaut adequate visual and reach envelopes. Previously, the initial location of these sockets was dependent upon the experienced designer's ability to estimate placement. The design was tested in a simulated zero-gravity environment; spacesuited astronauts performed the tasks with mockups while submerged in water. Crew evaluation of the tasks based on these designs often indicated the bolt or other structure to which force needed to be applied was not within an acceptable work envelope, resulting in redesign. The development of improved methods for location of crew aids prior to testing would result in savings to the design effort for EVA hardware. Such an effort to streamline EVA design is especially relevant to International Space Station construction and maintenance. Assembly operations alone are expected to require in excess of four hundred hours of EVA. Thus, techniques which conserve design resources for assembly missions can have significant impact. We describe an effort to implement a human modelling application in the design effort for an International Space Station Assembly Mission. On Assembly Flight 6A, the Canadian-built Space Station Remote Manipulator System will be delivered to the U.S. Laboratory. It will be released from its launch restraints by astronauts in EVA. The design of the placement of foot restraint sockets was carried out using the human model Jack, and the modelling results were compared with actual underwater test results. The predicted locations of the sockets was found to be acceptable for 94% of the tasks attempted by the astronauts, This effort provides confidence in the capabilities of this package to accurately model tasks. It therefore increases assurance that the tool maybe used early in the design process.

Dischinger, H. Charles↗
NASA NTRS2001

Improved Quick Disconnect (QD) Interface Through Fail Safe Parts Identification

An extensive review of existing Quick Disconnects (QDs) mating and demating operations was performed to determine which shuttle part interface identifications and procedures contribute to human factor errors. The research methods used consisted of interviews with engineers and technicians, examination of incident reports, critiques of video and audio tapes of QD operations, and attendance of a Hyper QD operational course. The data strongly suggests that there are inherit human factor errors involved in QD operations. To promote fail-safe operations, QD interface problem areas and recommendations were outlined and reviewed. It is suggested that dialogue, investigations and recommendations continue.

Blanch-Payne, Evelyn↗
NASA NTRS2010

Verification Challenges of Dynamic Testing of Space Flight Hardware

The Six Degree-of-Freedom Dynamic Test System (SDTS) is a test facility at the National Aeronautics and Space Administration (NASA) Johnson Space Center in Houston, Texas for performing dynamic verification of space structures and hardware. Some examples of past and current tests include the verification of on-orbit robotic inspection systems, space vehicle assembly procedures and docking/berthing systems. The facility is able to integrate a dynamic simulation of on-orbit spacecraft mating or demating using flight-like mechanical interface hardware. A force moment sensor is utilized for input to the simulation during the contact phase, thus simulating the contact dynamics. While the verification of flight hardware presents many unique challenges, one particular area of interest is with respect to the use of external measurement systems to ensure accurate feedback of dynamic contact. There are many commercial off-the-shelf (COTS) measurement systems available on the market, and the test facility measurement systems have evolved over time to include two separate COTS systems. The first system incorporates infra-red sensing cameras, while the second system employs a laser interferometer to determine position and orientation data. The specific technical challenges with the measurement systems in a large dynamic environment include changing thermal and humidity levels, operational area and measurement volume, dynamic tracking, and data synchronization. The facility is located in an expansive high-bay area that is occasionally exposed to outside temperature when large retractable doors at each end of the building are opened. The laser interferometer system, in particular, is vulnerable to the environmental changes in the building. The operational area of the test facility itself is sizeable, ranging from seven meters wide and five meters deep to as much as seven meters high. Both facility measurement systems have desirable measurement volumes and the accuracies vary within the respective volumes. In addition, because this is a dynamic facility with a moving test bed, direct line-of-sight may not be available at all times between the measurement sensors and the tracking targets. Finally, the feedback data from the active test bed along with the two external measurement systems must be synchronized to allow for data correlation. To ensure the desired accuracy and resolution of these systems, calibration of the systems must be performed regularly. New innovations in sensor technology itself are periodically incorporated into the facility s overall measurement scheme. In addressing the challenges of the measurement systems, the facility is able to provide essential position and orientation data to verify the dynamic performance of space flight hardware.

Winnitoy, Susan↗
NASA NTRS2012

Multi-Mission Radioisotope Thermoelectric Generator Heat Exchangers for the Mars Science Laboratory Rover

The addition of the Multi-Mission Radioisotope Thermoelectric Generator (MMRTG) to the Mars Science Laboratory (MSL) Rover requires an advanced thermal control system that is able to both recover and reject the waste heat from the MMRTG as needed in order to maintain the onboard electronics at benign temperatures despite the extreme and widely varying environmental conditions experienced both on the way to Mars and on the Martian surface. Based on the previously successful Mars landed mission thermal control schemes, a mechanically pumped fluid loop (MPFL) architecture was selected as the most robust and efficient means for meeting the MSL thermal requirements. The MSL heat recovery and rejection system (HRS) is comprised of two Freon (CFC-11) MPFLs that interact closely with one another to provide comprehensive thermal management throughout all mission phases. The first loop, called the Rover HRS (RHRS), consists of a set of pumps, thermal control valves, and heat exchangers (HXs) that enables the transport of heat from the MMRTG to the rover electronics during cold conditions or from the electronics straight to the environment for immediate heat rejection during warm conditions. The second loop, called the Cruise HRS (CHRS), is thermally coupled to the RHRS during the cruise to Mars, and provides a means for dissipating the waste heat more directly from the MMRTG as well as from both the cruise stage and rover avionics by promoting circulation to the cruise stage radiators. A multifunctional structure was developed that is capable of both collecting waste heat from the MMRTG and rejecting the waste heat to the surrounding environment. It consists of a pair of honeycomb core sandwich panels with HRS tubes bonded to both sides. Two similar HX assemblies were designed to surround the MMRTG on the aft end of the rover. Heat acquisition is accomplished on the interior (MMRTG facing) surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the fluid loops to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in-plane thermal conductivity and extremely low through-thickness thermal conductivity by using aluminum facesheets and aerogel as insulation inside a composite honeycomb core. Complex assemblies of hand-welded and uniquely bent aluminum tubes are bonded onto each side of the HX panels, and are specifically designed to be easily mated and demated to the rest of the RHRS in order to ease the integration effort.

Mastropietro, A. J.↗
NASA NTRS2010

Design and Preliminary Thermal Performance of the Mars Science Laboratory Rover Heat Exchangers

The challenging range of proposed landing sites for the Mars Science Laboratory Rover requires a rover thermal management system that is capable of keeping temperatures controlled across a wide variety of environmental conditions. On the Martian surface where temperatures can be as cold as -123 degrees Centigrade and as warm as 38 degrees Centigrade, the Rover relies upon a Mechanically Pumped Fluid Loop (MPFL) and external radiators to maintain the temperature of sensitive electronics and science instruments within a -40 degrees Centigrade to 50 degrees Centigrade range. The MPFL also manages significant waste heat generated from the Rover power source, known as the Multi Mission Radioisotope Thermoelectric Generator (MMRTG). The MMRTG produces 110 Watts of electrical power while generating waste heat equivalent to approximately 2000 Watts. Two similar Heat Exchanger (HX) assemblies were designed to both acquire the heat from the MMRTG and radiate waste heat from the onboard electronics to the surrounding Martian environment. Heat acquisition is accomplished on the interior surface of each HX while heat rejection is accomplished on the exterior surface of each HX. Since these two surfaces need to be at very different temperatures in order for the MPFL to perform efficiently, they need to be thermally isolated from one another. The HXs were therefore designed for high in-plane thermal conductivity and extremely low through-thickness thermal conductivity by using aerogel as an insulator inside composite honeycomb sandwich panels. A complex assembly of hand welded and uniquely bent aluminum tubes are bonded onto the HX panels and were specifically designed to be easily mated and demated to the rest of the Rover Heat Recovery and Rejection System (RHRS) in order to ease the integration effort. During the cruise phase to Mars, the HX assemblies serve the additional function of transferring heat from the Rover MPFL to the separate Cruise Stage MPFL so that heat generated deep inside the Rover can be dissipated via the Cruise Stage radiators. Significant fabrication challenges had to be overcome in order to make the HX design a reality. The cruise phase thermal performance of the Rover HXs was verified in the cruise phase system level thermal vacuum test that was performed at JPL in January of 2009. The Rover HXs were modeled in I-DEAS TMG and predictions are compared to actual data from the test.

Heat Rejection System↗
NASA NTRS1993

Performance measures from the explorer platform berthing experiment

The Explorer Platform is a Modular Mission Spacecraft: it has several subunits that are designed to be replaced on orbit. The Goddard Space Flight Center Robotics Lab undertook an experiment to evaluate various robotic approaches to replacing one of the units; a large (approximately 1 meter by 1 meter by 0.5 meter) power box. The hardware consists of a Robotics Research Corporation K-1607 (RRC) manipulator mounted on a large gantry robot, a Kraft handcontroller for teleoperation of RRC, a Lightweight Servicing Tool (LST) mounted on the RRC, and an Explorer Platform mockup (EP) with a removable box (MMS) that has fixtures that mate with the LST. Sensors include a wrist wrench sensor on the RRC and Capaciflectors mounted on the LST and the MMS. There are also several cameras, but no machine vision is used. The control system for the RRC is entirely written by Goddard; it consists of Ada code on three Multibus I 386/387 CPU boards doing the real-time robot control, and C on a 386 PC processing Capaciflector data. The gantry is not moved during this experiment. The task is the exchange of the MMS; it is removed and replaced. This involves four basic steps: mating the LST to the MMS, demating the MMS from the EP, mating the MMS to the EP, and demating the LST form the MMS. Each of the mating steps must be preceeded by an alignment to bring the mechanical fixtures within their capture range. Two basic approaches to alignment are explored: teleoperation with the operator viewing thru cameras, and Capaciflector based autonomy. To evaluate the two alignment approaches, several runs were run with each approach and the final pose was recorded. Comparing this to the ideal alignment pose gives accuracy and repeatability data. In addition the wrenches exerted during the mating tasks were recorded; this gives information on how the alignment step affects the mating step. There are also two approaches to mating; teleoperation, and impedance based autonomy. The wrench data taken during mating using these two approaches is used to evaluate them. Section 2 describes the alignment results, section 3 describes the mating results, and finally Section 4 gives some conclusions.

Leake, Stephen↗
NASA NTRS2012

SRMS Assisted Docking and Undocking for the Orbiter Repair Maneuver

As part of the Orbiter Repair Maneuver (ORM) planned for Return to Flight (RTF) operations, the Shuttle Remote Manipulator System (SRMS) must undock the Orbiter, maneuver it through a complex trajectory at extremely low rates, present it to an EVA crewman at the end of the Space Station Remote Manipulator System to perform the Thermal Protection System (TPS) repair, and then retrace back through the trajectory to dock the Orbiter with the Orbiter Docking System (ODS). The initial and final segments of this operation involve the interaction between the SRMS, ISS, Orbiter and ODS. Previously, a technique entitled "SRMS assisted docking" for installation of a payload to the ODS had been developed and was utilized for the Russian provided Docking Module on STS-74 during Shuttle-Mir missions and both the Node 1 and FGB elements on STS-88/Flight 2A. This procedure consisted of the SRMS grappling the respective payload, maneuvering it to a pre-install position inches above the ODS Androgynous Peripheral Attachment System (APAS) ring, commanding the SRMS into Test mode (which allows brakes-off motion of the joints), and then down-firing Primary Reaction Control System (PRCS) jets in order to effect a capture of the APAS latches. Once a successful capture had been achieved, then the AP AS was operated through its nominal retraction sequence to complete the mating sequence. While this technique can once again be used for the tail end docking portion of the ORM, the initial undocking of the orbiter and ISS vehicles with the assistance of the SRMS has yet to be attempted on orbit. The objective here is to determine the most efficient means to separate or extract the vehicles. Two techniques were analyzed in support of RTF: (1) the 'nominal' demating from the mated interface, and (2) the SRMS performing the operation (either in an active or passive fashion). In the first operation, the demating process would replicate standard undocking operations, with the exception that the SRMS is allowed to arrest the resulting motion. The second operation would be to extend the APAS ring to a ready to dock position, open the capture latches, and then detach the vehicles using the SRMS either actively or passively. In the active case, the APAS ring is extended and latched, and the SRMS is commanded to pull the two interfaces apart (assuming that the effective pull force of the SRMS can overcome the spec values of the combined latch resistance). In the passive case, the SRMS brakes are engaged and the AP AS mechanism is commanded to retract, pulling the two interfaces apart. Since the emphasis of both STS-74 and STS-88 had solely been on the installation operation, as opposed to the separation operation, two new models required development and incorporation within simulation tools designed to analyze those scenarios. These enhancements included: (1) a detailed demating dynamics model to characterize the pusher spring characteristics during undocking, and (2) contact and mechanical system modeling of the back side of the latches to represent unlatching dynamics. This paper first provides an overview of the Monte-Carlo screening analysis for the installation (both nominal and contingency), including the variation of separation distance, misalignment conditions, SRMS joint/brake parameter characteristics, and PRCS jet combinations and corresponding thrust durations. The resulting 'optimum' solution is presented based on trade studies between predicted capture success and integrated system loads. This paper then discusses the upgrades to the APAS math model associated with the new SRMS assisted undocking technique and reviews simulation results for various options investigated for either the active and passive separation of the ISS from the Orbiter.

Space Station Remote Manipulator System↗
NASA NTRS1998

Design Optimization and Analysis of a Composite Honeycomb Intertank

Intertanks, the structure between tanks of launch vehicles, are prime candidates for weight reduction of rockets. This paper discusses the optimization and detailed analysis of a 96 in (2.44 m) diameter, 77 in (1.85 m) tall intertank. The structure has composite face sheets and an aluminum honeycomb core. The ends taper to a thick built up laminate for a double lap bolted shear joint. It is made in 8 full length panels joined with bonded double lap joints. The nominal load is 4000 lb/in (7 x 10(exp 5) N/m). Optimization is by Genetic Algorithm and minimizes weight by varying C, core thickness, number and orientation of acreage and buildup plies, and the size, number and spacing of bolts. A variety of cases were run with populations up to 2000 and chromosomes as long as 150 bits. Constraints were buckling, face stresses (normal, shear, wrinkling and dimpling, bolt stress, and bolt hole stresses (bearing, net tension, wedge splitting, shear out and tension/shear out). Analysis is by a combination of theoretical solutions and empirical data. After optimization, a series of coupon tests were performed in conjunction with a rigorous analysis involving a variety of finite element models. The analysis and test resulted in several small changes to the optimized design. The intertank has undergone a 250,000 lb (1.1 x 10(exp 6) N) limit load test and been mated with a composite liquid hydrogen tank. The tank/intertank unit is being installed in a test stand where it will see 200 thermal/load cycles. Afterwards the intertank will be demated and loaded in compression to failure.

Finckenor, Jeffrey↗
NASA NTRS1999

Design Optimization and Analysis of a Composite Honeycomb Intertank

Intertanks, the structure between tanks of launch vehicles, are prime candidates for weight reduction of rockets. This paper discusses the optimization and detailed follow up analysis and testing of a 96 in. diameter, 77 in. tall intertank. The structure has composite face sheets with an aluminum honeycomb core. The ends taper to a thick built up laminate for a double lap bolted splice joint interface. It is made in 8 full length panels joined with bonded double lap joints. The nominal load is 4000 lb/in. Optimization is by Genetic Algorithm and minimizes weight by varying core thickness, number and orientation of acreage and buildup plies, and the size, number and spacing of bolts. A variety of design cases were run with populations up to 2000 and chromosomes as long as 150 bits. Constraints were buckling; face stresses (normal, shear, wrinkling and dimpling); bolt stress; and bolt hole stresses (bearing, net tension, wedge splitting, shear out and tension/shear out). Analysis is by a combination of elasticity solutions and empirical data. After optimization, a series of coupon tests were performed in conjunction with a rigorous analysis involving a variety of finite element models. This analysis and testing resulted in several small changes to the optimized design. The equation used for hole bearing strength was found to be inadequate, resulting in thicker ends. The core thickness increased 0.05", and potting compound was added in the taper to strengthen the facesheet bond. The intertank has undergone a 250,000 lb limit load test and been mated with a composite liquid hydrogen tank. The tank/intertank unit is being installed in a test stand where it will see 200 thermal/load cycles. Afterwards the intertank will be demated and loaded in compression to failure.

Finckenor, Jeff↗