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NASA NTRS2016

Large Payload Ground Transportation and Test Considerations

During test and verification planning for the Altair lunar lander project, a National Aeronautics and Space Administration (NASA) study team identified several ground transportation and test issues related to the large payload diameter. Although the entire Constellation Program-including Altair-has since been canceled, issues identified by the Altair project serve as important lessons learned for payloads greater than 7 m diameter being considered for NASA's new Space Launch System (SLS). A transportation feasibility study found that Altair's 8.97 m diameter Descent Module would not fit inside available aircraft. Although the Ascent Module cabin was only 2.35 m diameter, the long reaction control system booms extended nearly to the Descent Module diameter, making it equally unsuitable for air transportation without removing the booms and invalidating assembly workmanship screens or acceptance testing that had already been performed. Ground transportation of very large payloads over extended distances is not generally permitted by most states, so overland transportation alone would not be an option. Limited ground transportation to the nearest waterway may be possible, but water transportation could take as long as 66 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA's Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing such as hypergolic fuels, pyrotechnic devices, and high pressure gasses. Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure-roads, bridges, airframes, and buildings-necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider where and how large spacecraft are manufactured, tested, and launched could result in unforeseen cost to modify existing (or develop new) infrastructure, or incur additional risk due to increased handling operations or eliminating key verifications.

Rucker, Michelle A.↗

NASA NTRS2016

Large Payload Ground Transportation and Test Considerations

Many spacecraft concepts under consideration by the National Aeronautics and Space Administration’s (NASA’s) Evolvable Mars Campaign take advantage of a Space Launch System payload shroud that may be 8 to 10 meters in diameter. Large payloads can theoretically save cost by reducing the number of launches needed--but only if it is possible to build, test, and transport a large payload to the launch site in the first place. Analysis performed previously for the Altair project identified several transportation and test issues with an 8.973 meters diameter payload. Although the entire Constellation Program—including Altair—has since been canceled, these issues serve as important lessons learned for spacecraft designers and program managers considering large payloads for future programs. A transportation feasibility study found that, even broken up into an Ascent and Descent Module, the Altair spacecraft would not fit inside available aircraft. Ground transportation of such large payloads over extended distances is not generally permitted, so overland transportation alone would not be an option. Limited ground transportation to the nearest waterway may be possible, but water transportation could take as long as 67 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA’s Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing such as hypergolic fuels, pyrotechnic devices, and high pressure gasses. Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure—roads, bridges, airframes, and buildings—necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider where and how large spacecraft are manufactured, tested, and launched could result in unforeseen cost to modify existing (or develop new) infrastructure, or incur additional risk due to increased handling operations or eliminating key verifications. Although this paper focuses on the canceled Altair spacecraft as a case study, the issues identified here have wide applicability to other large payloads, including concepts under consideration for NASA’s Evolvable Mars Campaign.

Rucker, Michelle A.↗

NASA NTRS1988

Orbital debris environment for spacecraft designed to operate in low Earth orbit

The orbital debris environment model is intended to be used by the spacecraft community for the design and operation of spacecraft in low Earth orbit. This environment, when combined with material-dependent impact tests and spacecraft failure analysis, is intended to be used to evaluate spacecraft vulnerability, reliability, and shielding requirements. The environment represents a compromise between existing data to measure the environment, modeling of this data to predict the future environment, the uncertainty in both measurements and modeling, and the need to describe the environment so that various options concerning spacecraft design and operations can be easily evaluated.

Kessler, Donald J.↗

NASA NTRS1985

Review of the NASA Voyager spacecraft polycarbonate capacitor failure incident

The premission failure of a Voyager spacecraft capacitor has prompted an investigation into the use of polycarbonate capacitors in high impedance circuits, during which capacitor failures were induced by thermal cycling together with extended periods at high temperature. Measurement of leakage path temperature coefficients indicates that there are two distinct leakage types whose mechanisms are complicated by movement within the capacitor during temperature changes. A novel system for pulse detection during capacitor burn-in and ramp testing has proven to be beneficial.

Ott, F. M.↗

NASA NTRS1996

The search for materials to mitigate spacecraft charging

As spacecraft orbit the earth, they encounter a variety of particles and radiation. Charged particles are common enough that a spacecraft can collect substantial charges on its surfaces. If these charges are not bled off, they can accumulate until electrostatic discharges occur between a charged surface and some lower-potential location on the craft. Electrostatic discharge (ESD) is the suspected culprit in a number of spacecraft failures. Silverized Teflon film has become the standard heat-reflecting outer layer of spacecraft because of its flexibility, chemical inertness, and low volatiles content. However, as spacecraft are designed to operate in orbits with greater probability of accumulating enough ions and electrons to create ESD, the Teflon-based thermal control blankets are becoming a liability. Unless stringent (and sometimes burdensome) shielding measures are taken, ESD can upset delicate electronic systems by upsetting or destroying components, interfering with radio signals, garbling internal instructions, and so on. As orbits become higher and more eccentric, as electronics become more sensitive, and as fault-free operation becomes more crucial, it is becoming necessary to find a replacement for silver/Teflon that has comparable strength, flexibility and chemical inertness, as well as a much lower potential for ESD. This is a report of the steps taken toward the goal of selecting a replacement for silver/Teflon during the Summer of 1995. It is a condensation of a much larger report available on request from the author. Three tasks were undertaken. Task 1 was to specify desirable properties for thermal control blankets. The second task was to collect data on materials properties from the literature and organize into a format useful for identifying candidate materials. The third task was to identify candidate materials and begin testing.

Losure, Nancy S.↗

NASA NTRS2003

New NASA SEE LEO Spacecraft Charging Design Guidelines: How to Survive in LEO Rather Than GEO

It has been almost two solar cycles since the 1984 GEO Guidelines of Purvis, Garrett, Whittlesey, and Stevens were published. In that time, interest in high voltage LEO systems has increased. Correct and conventional wisdom has been that LEO conditions are sufficiently different from GEO that the GEO Guidelines (and other GEO and POLAR documents produced since then) should not be used for LEO spacecraft. Because of significant recent GEO spacecraft failures that have been shown in ground testing to be likely to also occur on LEO spacecraft, the SEE program commissioned the production of the new LEO Spacecraft Charging Design Guidelines. Now available in CD-ROM form, the LEO Guidelines highlight mitigation techniques to prevent spacecraft arcing on LEO solar arrays and other systems. We compare and contrast the mitigation techniques for LEO and GEO in this paper. We also discuss the extensive bibliography included in the LEO Guidelines, so results can be found in their primary sources.

Ferguson, Dale C.↗

NASA NTRS2004

New NASA SEE LEO Spacecraft Charging Design Guidelines: How to Survive in LEO Rather than GEO

It has been almost two solar cycles since the GEO Guidelines of Purvis et al (1984) were published. In that time, interest in high voltage LEO systems has increased. The correct and conventional wisdom has been that LEO conditions are sufficiently different from GEO that the GEO Guidelines (and other GEO and POLAR documents produced since then) should not be used for LEO spacecraft. Because of significant recent GEO spacecraft failures that have been shown in ground testing to be likely to also occur on LEO spacecraft, the SEE program commissioned the production of the new LEO Spacecraft Charging Design Guidelines (hereafter referred to as the LEO Guidelines). Now available in CD-ROM form, the LEO Guidelines highlight mitigation techniques to prevent spacecraft arcing on LEO solar arrays and other systems. We compare and contrast the mitigation techniques for LEO and GEO in this paper. We also discuss the extensive bibliography included in the LEO Guidelines, so results can be found in their primary sources.

Ferguson, Dale C.↗

NASA NTRS2016

Crew Exploration Vehicle (CEV) (Orion) Occupant Protection

Dr. Nancy J. Currie, of the NASA Engineering and Safety Center (NESC), Chief Engineer at Johnson Space Center (JSC), requested an assessment of the Crew Exploration Vehicle (CEV) occupant protection as a result of issues identified by the Constellation Program and Orion Project. The NESC, in collaboration with the Human Research Program (HRP), investigated new methods associated with occupant protection for the Crew Exploration Vehicle (CEV), known as Orion. The primary objective of this assessment was to investigate new methods associated with occupant protection for the CEV, known as Orion, that would ensure the design provided minimal risk to the crew during nominal and contingency landings in an acceptable set of environmental and spacecraft failure conditions. This documents contains the outcome of the NESC assessment. NASA/TM-2013-217380, "Application of the Brinkley Dynamic Response Criterion to Spacecraft Transient Dynamic Events." supercedes this document.

Currie-Gregg, Nancy J.↗

NASA NTRS2016

Crew Exploration Vehicle (CEV) (Orion) Occupant Protection: Appendices - Part 1

Dr. Nancy J. Currie, of the NASA Engineering and Safety Center (NESC), Chief Engineer at Johnson Space Center (JSC), requested an assessment of the Crew Exploration Vehicle (CEV) occupant protection as a result of issues identified by the Constellation Program and Orion Project. The NESC, in collaboration with the Human Research Program (HRP), investigated new methods associated with occupant protection for the Crew Exploration Vehicle (CEV), known as Orion. The primary objective of this assessment was to investigate new methods associated with occupant protection for the CEV, known as Orion, that would ensure the design provided minimal risk to the crew during nominal and contingency landings in an acceptable set of environmental and spacecraft failure conditions. This documents contains the appendices to the NESC assessment report. NASA/TM-2013-217380, Application of the Brinkley Dynamic Response Criterion to Spacecraft Transient Dynamic Events supersedes this document.

Currie-Gregg, Nancy J.↗

NASA NTRS1972

ATS-5 solar cell experiment results after one year in synchronous orbit

The results of the ATS-5 solar cell experiment after one year in synchronous orbit are reported. A partial failure in the experimental electronics package has caused a loss of data from half the 80 experimental solar cells. Procedures for extracting data due to a partial spacecraft failure are described and discussed. Data from the remaining 40 solar cells, including 15 mounted on a thin flexible structure are analyzed. Data are corrected to a solar intensity of 140 mW/sq cm and a temperature of 25 C. It was found that after one year in synchronous orbit: (1) cells with 1.52-mm-thick coverslides did not show a clear-cut advantage over those with 0.15-mm coverslides, (2) cells with solderless grid lines are degrading at the same rate as are cells with solder-dipped grid lines, (3) cells not quite completely covered with coverslides suffered a large power loss in comparison to cells fully covered, (4) no clear-cut advantage of 10-cm cells over 2-cm cells has yet been observed, (5) cells mounted on the flexible panel with relatively little backshielding did not degrade any faster than those with substantial backshielding, and (6) the flight data in large part confirms the adequacy of the ground-based techniques used in our preflight radiation test program.

Anspaugh, B. E.↗

NASA NTRS2012

Space Weather Impacts on Spacecraft Design and Operations in Auroral Charging Environments

Spacecraft in low altitude, high inclination (including sun-synchronous) orbits are widely used for remote sensing of the Earth s land surface and oceans, monitoring weather and climate, communications, scientific studies of the upper atmosphere and ionosphere, and a variety of other scientific, commercial, and military applications. These systems are episodically exposed to environments characterized by a high flux of energetic (approx.1 to 10 s kilovolt) electrons in regions of very low background plasma density which is similar in some ways to the space weather conditions in geostationary orbit responsible for spacecraft charging to kilovolt levels. While it is well established that charging conditions in geostationary orbit are responsible for many anomalies and even spacecraft failures, to date there have been relatively few such reports due to charging in auroral environments. This presentation first reviews the physics of the space environment and its interactions with spacecraft materials that control auroral charging rates and the anticipated maximum potentials that should be observed on spacecraft surfaces during disturbed space weather conditions. We then describe how the theoretical values compare to the observational history of extreme charging in auroral environments and discuss how space weather impacts both spacecraft design and operations for vehicles on orbital trajectories that traverse auroral charging environments.

Minow, Joseph I.↗

NASA NTRS1972

Use of the space shuttle to avoid spacecraft anomalies

An existing data base covering 304 spacecraft of the U.S. space program was analyzed to determine the effect on individual spacecraft failures and other anomalies that the space shuttle might have had if it had been operational throughout the period covered by the data. By combining the results of this analysis, information on the prelaunch activities of selected spacecraft programs, and shuttle capabilities data, the potential impact of the space shuttle on future space programs was derived. The shuttle was found to be highly effective in the prevention or correction of spacecraft anomalies, with 887 of 1,230 anomalies analyzed being favorably impacted by full utilization of shuttle capabilities. The shuttle was also determined to have a far-reaching and favorable influence on the design, development, and test phases of future space programs. This is documented in 37 individual statements of impact.

Source record↗

NASA NTRS2011

High Energy Failure Containment for Spacecraft

Objective: The objective of this paper will be to investigate advancements and any commonality between spacecraft debris containment and the improvements being made in ballistic protection. Scope: This paper will focus on cross application of protection devices and methods, and how they relate to protecting humans from failures in spacecraft. The potential gain is to reduce the risk associated with hardware failure, while decreasing the weight and size of energy containment methods currently being used by the government and commercial industry. Method of Approach: This paper will examine testing that has already been accomplished in regards to the failure of high energy rotating hardware and compare it to advancements in ballistic protection. Examples are: DOT research and testing of turbine containment as documented in DOT/FAA/AR-96/110, DOT/FAA/AR-97/82, DOT/FAA/AR-98/22. It will also look at work accomplished by companies such as ApNano and IBD Deisenroth in the development of nano ceramics and nanometric steels. Other forms of energy absorbent materials and composites will also be considered and discussed. New Advances in State of the Art: There have been numerous advances in technology in regards to high energy debris containment and in the similar field of ballistic protection. This paper will discuss methods such as using impregnated or dry Kevlar, ceramic, and nano-technology which have been successfully tested but are yet to be utilized in spacecraft. Reports on tungsten disulfide nanotubes claim that they are 4-5 times stronger than steel and reports vary about the magnitude increase over Kevlar, but it appears to be somewhere in the range of 2-6 times stronger. This technology could also have applications in the protection of pressure vessels, motor housings, and hydraulic component failures.

Pektas, Pete↗

NASA NTRS1986

ICE encounter operations

The operations encompassing the International Cometary Explorer's (ICE) encounter with the Comet Giacobini-Zinner on September 11, 1985 are documented. The ICE mission presented new challenges for the Deep Space Network (DSN) 64 meter subnetwork. Because of poor telemetry link margin predicted for Giacobini-Zinner (GZ) encounter, supplemental support by the Japanese Institute for Space and Astronautical Sciences 64-meter antenna at Usuda, Japan and the 305-meter Arecibo Radio Observatory in Puerto Rico was required. To improve the 64 meter subnetwork telemetry performance the following were also implemented: (1) Real time antenna array of 64 meter and 34 meter at a single complex and the required performance testing; and (2) Nonreal time antenna array of two complexes was implemented as a backup in the event of ground or spacecraft failure.

Fanelli, N.↗

NASA NTRS1991

Seasat-A - A retrospective

This paper traces the highlights of the Seasat-A project from its earliest conceptual phases through the orbital operations phase. The primary objective of the project was to demonstrate the feasibility of remotely sensing fundamental oceanographic phenomena on a global, accurate, reliable and timely basis from an earth-orbiting platform. The project successfully achieved its primary objective, in spite of a premature spacecraft failure, and thus provided a firm basis for the development of sensors for future ocean-observing space missions.

Giberson, W. E.↗

NASA NTRS1991

TALON and CRADLE: Systems for the rescue of tumbling spacecraft and astronauts

Advanced pressure suit and tool designs are beginning to allow extravehicular astronauts to repair space vehicles and so increase mission life and system reliability. A common spacecraft failure that is a severe challenge to the rescue mission planner is loss of attitude control resulting in tumbling motion. If an extravehicular astronaut flying the Manned Maneuvering Unit (MMU) 'falls' into a tumble, the result could be loss of life. TALON (Tumble Arresting Large Oscillation Nullifier) is a device capable of capturing a target in an uncontrolled three-axis tumble. CRADLE (Concentric Rotating Astronaut Detumble Lifesaving Equipment) is a similar device sized to rescue a suited astronaut. The two rescue vehicles work on the same basic principle. They are structural shells with articulated limbs which can surround a tumbling target and thus align both the chaser and target centers of mass (CM).

Idle, Dunning, V↗

NASA NTRS1997

Development of Tailorable Electrically Conductive Thermal Control Material Systems

The optical characteristics of surfaces on spacecraft are fundamental parameters in controlling its temperature. Passive thermal control coatings with designed solar absorptance and infrared emittance properties have been developed and have been in use for some time. In this total space environment, the coating must be stable and maintain its desired optical properties as well as mechanical properties for the course of the mission lifetime. The mission lifetimes are increasing and in our quest to save weight, newer substrates are being integrated which limit electrical grounding schemes. All of this has added to already existing concerns about spacecraft charging and related spacecraft failures or operational failures. The concern is even greater for thermal control surfaces that are very large. One way of alleviating such concerns is to design new thermal control material systems (TCMS) that can help to mitigate charging via providing charge leakage paths. The objective of this program was to develop two types of passive electrically conductive TCMS. The first was a highly absorbing/emitting black surface and the second was a low (alpha(sub s)/epsilon(sub N)) type white surface. The surface resistance goals for the black absorber was 10(exp 4) to 10(exp 9) Omega/square, and for the white surfaces it was 10(exp 6) to 10(exp 10) Omega/square. Several material system concepts were suggested and evaluated for space environment stability and electrical performance characterization. Our efforts in designing and evaluating these material systems have resulted in several developments. New concepts, pigments and binders have been developed to provide new engineering quality TCMS. Some of these have already found application on space hardware, some are waiting to be recognized by thermal designers, and some require further detailed studies to become state-of-the-art for future space hardware and space structures. Our studies on baseline state-of-the-art materials and conductive concepts have resulted in several important findings that are of interest to all thermal designers and systems integrators.

Deshpande, M. S.↗

NASA NTRS1998

Development of Tailorable Electrically Conductive Thermal Control Material Systems

Deshpande, M. S.↗