ISS Lessons Learned, Looking ahead to Artemis
A review of some lessons from integrated testing for the International Space Station and applying those lessons toward aspects of the Artemis campaign.
International Space Station↗
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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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Fiber optic (flight quality) sensors for advanced aircraft propulsion
Development of flight prototype, fiber-optic sensing system components for measuring nine sensed parameters (three temperatures, two speeds, three positions, and one flame) on an F404-400 aircraft engine is described. Details of each sensor's design, functionality, and environmental testing, and the electro-optics architecture for sensor signal conditioning are presented. Eight different optical sensing techniques were utilized. Design, assembly, and environmental testing of an engine-mounted, electro-optics chassis unit (EOU), providing MIL-C-1553 data output, are related. Interconnection cables and connectors between the EOU and the sensors are identified. Results of sensor/cable/circuitry integrated testing, and installation and ground testing of the sensor system on an engine in October 1993 and April 1994 are given, including comparisons with the engine control system's electrical sensors. Lessons learned about the design, fabrication, testing, and integration of the sensor system components are included.
Poppel, Gary L.↗
The MIST (Minus Integration and Subsystems Test) Laboratory: A testbed for the MIUS (Modular Integrated Utility System) program
The MIUS program develops an economically feasible integrated utility system. The MIUS concept integrates utility services in order to achieve resource, energy and environmental benefits. A testbed integrated utility system, called the MIST laboratory, was completed early in 1974 and has begun a long term program to develop data for MIUS. A description of the MIST is presented and the critical design issues which can only be verified by test, are discussed in detail.
Beckham, W. S., Jr.↗
Challenges of the Cassini Test Bed Simulating the Saturnian Environment
The Cassini-Huygens mission is a joint NASA and European Space Agency (ESA) mission to collect scientific data of the Saturnian system and is managed by the Jet Propulsion Laboratory (JPL). After having arrived in Saturn orbit and releasing the ESA's Huygens probe for a highly successful descent and landing mission on Saturn's moon Titan, the Cassini orbiter continues on its tour of Saturn, its satellites, and the Saturnian environment. JPL's Cassini Integrated Test laboratory (ITL) is a dedicated high fidelity test bed that verifies and validates command sequences and flight software before upload to the Cassini spacecraft. The ITL provides artificial stimuli that allow a highly accurate hardware-in-the-loop test bed model that tests the operation of the Cassini spacecraft on the ground. This enables accurate prediction and recreation of mission events and flight software and hardware behavior. As we discovered more about the Saturnian environment, a combination of creative test methods and simulation changes were necessary to simulate the harmful effect that the optical and physical environment has on the pointing performance of Cassini. This paper presents the challenges experienced and overcome in that endeavor to simulate and test the post Saturn Orbit Insertion (SOI) and Probe Relay tour phase of the Cassini mission.
Titan atmospheric drag↗
Integration and flight demonstration of a high-capacity monogroove heat-pipe radiator
The cancellation of the TDRS-B satellite as the payload for the eighth Space Shuttle mission provided a unique opportunity to demonstrate on-orbit operation of the high-capacity monogroove heat pipe used in the space constructible radiator subsystem. In less than 4 months, a flight experiment was conceived, designed, fabricated, tested, integrated with a payload carrier, installed in the Orbiter Challenger payload bay, and successfully operated in flight. Still color photographs and direct crew visual observation of color changes in a pattern of temperature-sensitive liquid-crystal tapes provided the temperature data necessary to verify successful on-orbit startup and orbital transient response of the heat pipe when subjected to a heat load from its attached electrical heaters. This successful on-orbit demonstration verified analytical design tools and provided confidence in the use of high-capacity heat pipes for future space applications. The flight experiment hardware and the integration and test activities that led to the flight are described, and the actual flight results are compared to analytical performance predictions.
Rankin, J. G.↗
Countermeasure Evaluation and Validation Project (CEVP) Database Requirement Documentation
The initial focus of the project by the JSC laboratories will be to develop, test and implement a standardized complement of integrated physiological test (Integrated Testing Regimen, ITR) that will examine both system and intersystem function, and will be used to validate and certify candidate countermeasures. The ITR will consist of medical requirements (MRs) and non-MR core ITR tests, and countermeasure-specific testing. Non-MR and countermeasure-specific test data will be archived in a database specific to the CEVP. Development of a CEVP Database will be critical to documenting the progress of candidate countermeasures. The goal of this work is a fully functional software system that will integrate computer-based data collection and storage with secure, efficient, and practical distribution of that data over the Internet. This system will provide the foundation of a new level of interagency and international cooperation for scientific experimentation and research, providing intramural, international, and extramural collaboration through management and distribution of the CEVP data. The research performed this summer includes the first phase of the project. The first phase of the project is a requirements analysis. This analysis will identify the expected behavior of the system under normal conditions and abnormal conditions; that could affect the system's ability to produce this behavior; and the internal features in the system needed to reduce the risk of unexpected or unwanted behaviors. The second phase of this project have also performed in this summer. The second phase of project is the design of data entry screen and data retrieval screen for a working model of the Ground Data Database. The final report provided the requirements for the CEVP system in a variety of ways, so that both the development team and JSC technical management have a thorough understanding of how the system is expected to behave.
Shin, Sung Y.↗
Avionics Architectures for Exploration: Ongoing Efforts in Human Spaceflight
The field of Avionics is advancing far more rapidly in terrestrial applications than in spaceflight applications. Spaceflight Avionics are not keeping pace with expectations set by terrestrial experience, nor are they keeping pace with the need for increasingly complex automation and crew interfaces as we move beyond Low Earth Orbit. NASA must take advantage of the strides being made by both space-related and terrestrial industries to drive our development and sustaining costs down. This paper describes ongoing efforts by the Avionics Architectures for Exploration (AAE) project chartered by NASA's Advanced Exploration Systems (AES) Program to evaluate new avionic architectures and technologies, provide objective comparisons of them, and mature selected technologies for flight and for use by other AES projects. The AAE project team includes members from most NASA centers, and from industry. It is our intent to develop a common core avionic system that has standard capabilities and interfaces, and contains the basic elements and functionality needed for any spacecraft. This common core will be scalable and tailored to specific missions. It will incorporate hardware and software from multiple vendors, and be upgradeable in order to infuse incremental capabilities and new technologies. It will maximize the use of reconfigurable open source software (e.g., Goddard Space Flight Center's (GSFC's) Core Flight Software (CFS)). Our long-term focus is on improving functionality, reliability, and autonomy, while reducing size, weight, and power. Where possible, we will leverage terrestrial commercial capabilities to drive down development and sustaining costs. We will select promising technologies for evaluation, compare them in an objective manner, and mature them to be available for future programs. The remainder of this paper describes our approach, technical areas of emphasis, integrated test experience and results as of mid-2014, and future plans. As a part of the AES Program, we are encouraged to set aggressive goals and fall short if necessary, rather than to set our sights too low. We are also asked to emphasize providing our personnel with hands-on experience in development, integration, and testing. That we have embraced both of these philosophies will be evident in the descriptions below.
Goforth, Montgomery B.↗
Performance measurements for a laboratory-simulated 30/20 GHz communication satellite transponder
NASA has developed a digital satellite communications system simulator and test bed facility, known as the Systems Integration, Test and Evaluation (SITE) Project. The purpose of the facility is to evaluate satellite system components, develop and verify system concepts, and perform satellite system experiments. A recently completed set of experiments measured the performance of the 30/20 GHz satellite transponder portion of the system in terms of RF parameters and high rate digital data transmission. The results of these tests indicate the quality of data transmission which can be obtained under various transponder conditions, as well as the relative effects of degraded RF performance on the bit-error rate (BER) of transmitted data.
Kerczewski, Robert J.↗
The Cryogenic Test Bed experiments: Cryogenic heat pipe flight experiment CRYOHP (STS-53). Cryogenic two phase flight experiment CRYOTP (STS-62). Cryogenic flexible diode flight experiment CRYOFD
This paper presents an overview of the Cryogenic Test Bed (CTB) experiments including experiment results, integration techniques used, and lessons learned during integration, test and flight phases of the Cryogenic Heat Pipe Flight Experiment (STS-53) and the Cryogenic Two Phase Flight Experiment (OAST-2, STS-62). We will also discuss the Cryogenic Flexible Diode Heat Pipe (CRYOFD) experiment which will fly in the 1996/97 time frame and the fourth flight of the CTB which will fly in the 1997/98 time frame. The two missions tested two oxygen axially grooved heat pipes, a nitrogen fibrous wick heat pipe and a 2-methylpentane phase change material thermal storage unit. Techniques were found for solving problems with vibration from the cryo-collers transmitted through the compressors and the cold heads, and mounting the heat pipe without introducing parasitic heat leaks. A thermally conductive interface material was selected that would meet the requirements and perform over the temperature range of 55 to 300 K. Problems are discussed with the bi-metallic thermostats used for heater circuit protection and the S-Glass suspension straps originally used to secure the BETSU PCM in the CRYOTP mission. Flight results will be compared to 1-g test results and differences will be discussed.
Thienel, Lee↗
Exploration System Mission Directorate and Constellation Program Support for Analogue Missions
Vision: To create a cross-cutting Earth-based program to minimize cost and risk while maximizing the productivity of planetary exploration missions, by supporting precursor system development and carrying out system integration, testing, training, and public engagement as an integral part of the Vision for Space Exploration.
Hoffman, Stephen J.↗
Modular, Reconfigurable, and Rapid Response Space Systems: The Remote Sensing Advanced Technology Microsatellite
Modular, Reconfigurable, and Rapid-response (MR(sup 2)) space systems represent a paradigm shift in the way space assets of all sizes are designed, manufactured, integrated, tested, and flown. This paper will describe the MR(sup 2) paradigm in detail, and will include guidelines for its implementation. The Remote Sensing Advanced Technology microsatellite (RSAT) is a proposed flight system test-bed used for developing and implementing principles and best practices for MR(sup 2) spacecraft, and their supporting infrastructure. The initial goal of this test-bed application is to produce a lightweight (approx. 100 kg), production-minded, cost-effective, and scalable remote sensing micro-satellite capable of high performance and broad applicability. Such applications range from future distributed space systems, to sensor-webs, and rapid-response satellite systems. Architectures will be explored that strike a balance between modularity and integration while preserving the MR(sup 2) paradigm. Modularity versus integration has always been a point of contention when approaching a design: whereas one-of-a-kind missions may require close integration resulting in performance optimization, multiple and flexible application spacecraft benefit &om modularity, resulting in maximum flexibility. The process of building spacecraft rapidly (< 7 days), requires a concerted and methodical look at system integration and test processes and pitfalls. Although the concept of modularity is not new and was first developed in the 1970s by NASA's Goddard Space Flight Center (Multi-Mission Modular Spacecraft), it was never modernized and was eventually abandoned. Such concepts as the Rapid Spacecraft Development Office (RSDO) became the preferred method for acquiring satellites. Notwithstanding, over the past 30 years technology has advanced considerably, and the time is ripe to reconsider modularity in its own right, as enabler of R(sup 2), and as a key element of transformational systems. The MR2 architecture provides a competitive advantage over the old modular approach in its rapid response to market needs that are difficult to predict both from the perspectives of evolving technology, as well as mission and application requirements.
Esper, Jaime↗
CanSat Competition: Contributing to the Development of NASA's Vision for Robotic Space Exploration
CanSat is an international student design-build-launch competition organized by the American Astronautical Society (AAS) and American Institute of Aeronautics and Astronautics (AIAA). The competition is also sponsored by the Naval Research Laboratory (NRL) and the National Aeronautics and Space Administration (NASA). The CanSat competition is designed for college, university and high school students wanting to participate in an applicable space-related competition. The objective of the CanSat competition is to complete space exploration missions by designing a specific system for a small sounding rocket payload which will follow and perform to a specific set of rules and guidelines for each year's competition. The competition encompasses a complete life-cycle of one year which includes all phases of design, integration, testing, judging and competition. The mission guidelines are based from space exploration missions and include bonus requirement options which teams may choose to participate in. The fundamental goal of the competition is to educate future engineers and scientists. This is accomplished by students applying systems engineering practices to a development project that incorporates an end-to-end life cycle, from requirements analysis, through preliminary design, integration and testing, an actual flight of the CanSat, and concluding with a post-mission debrief. This is done specifically with space related missions to bring a unique aspect of engineering and design to the competition. The competition has been progressing since its creation in 2005. The competition was originally meant to purely convey the engineering and design process to its participants, but through many experiences the competition has also undergone a learning experience with respect to systems engineering process and design. According
Berman, Joshua↗
Lessons Learned in Space Life Support System Testing
The earlier problems can be found and corrected, the easier and cheaper it is to fix them. Doing less testing saves cost and time but doing too little testing increases the risk of operational failures causing large costs and delays. Integrated test is necessary to determine if the subsystems work together and the overall architecture performs as intended. This report reviews the testing lessons learned from the NASA Systems Engineering Handbook, a National Research Council report, and five reviews of International Space Station (ISS) lessons learned. The five reviews all mention two important points. First, that testing should be performed on the final integrated system, one as close as possible to the intended flight system. Second, “test as you fly,” while operating as planned in an environment as close as possible to the expected flight environment. Other lessons are the need for extensive preflight ground testing, the need to establish and defend an adequate budget, the problems using protoflight hardware on ISS, and the benefit of having ISS as a zero gravity test bed. The major ISS life support systems, carbon dioxide, water recycling, and oxygen recovery, were protoflight systems with little testing before launch to ISS. The failure rates these systems have been much greater than predicted and this has caused dissatisfaction with the protoflight approach. The more costly traditional approach is building qualification and test units in addition to flight units. The test units are used to test, analyze, and fix failure modes. Other work shows that there is an optimum cost-effective intuitive appeal of a human ecosystem in space.
Life support↗
Lessons Learned in Space Life Support System Testing
The earlier problems can be found and corrected, the easier and cheaper it is to fix them. Doing less testing saves cost and time but doing too little testing increases the risk of operational failures causing large costs and delays. Integrated test is necessary to determine if the subsystems work together and the overall architecture performs as intended. This report reviews the testing lessons learned from the NASA Systems Engineering Handbook, a National Research Council report, and five reviews of International Space Station (ISS) lessons learned. The five reviews all mention two important points. First, that testing should be performed on the final integrated system, one as close as possible to the intended flight system. Second, “test as you fly,” while operating as planned in an environment as close as possible to the expected flight environment. Other lessons are the need for extensive preflight ground testing, the need to establish and defend an adequate budget, the problems using protoflight hardware on ISS, and the benefit of having ISS as a zero gravity test bed. The major ISS life support systems, carbon dioxide removal, water recycling, and oxygen recovery, were protoflight systems with little testing before launch to ISS. The failure rates of these systems have been much greater than predicted and this has caused dissatisfaction with the protoflight approach. The more costly traditional approach builds qualification and test units in addition to flight units. The test units are used to find, analyze, and fix failure modes. Other work shows that there is an optimum cost-effective amount of testing when redundant systems must have a specified reliability and confidence.
Harry W. Jones↗
AutoGNC Testbed
A simulation testbed architecture was developed and implemented for the integration, test, and development of a TRL-6 flight software set called Auto- GNC. The AutoGNC software will combine the TRL-9 Deep Impact AutoNAV flight software suite, the TRL-9 Virtual Machine Language (VML) executive, and the TRL-3 G-REX guidance, estimation, and control algorithms. The Auto- GNC testbed was architected to provide software interface connections among the AutoNAV and VML flight code written in C, the G-REX algorithms in MATLAB and C, stand-alone image rendering algorithms in C, and other Fortran algorithms, such as the OBIRON landmark tracking suite. The testbed architecture incorporates software components for propagating a high-fidelity truth model of the environment and the spacecraft dynamics, along with the flight software components for onboard guidance, navigation, and control (GN&C). The interface allows for the rapid integration and testing of new algorithms prior to development of the C code for implementation in flight software. This testbed is designed to test autonomous spacecraft proximity operations around small celestial bodies, moons, or other spacecraft. The software is baselined for upcoming comet and asteroid sample return missions. This architecture and testbed will provide a direct improvement upon the onboard flight software utilized for missions such as Deep Impact, Stardust, and Deep Space 1.
Carson, John M., III↗
Application of the Life Safety Code to a Historic Test Stand
NASA has conducted a study to assess alternatives to refurbishing existing launch vehicle modal test facilities as opposed to developing new test facilities to meet the demands of a very fiscally constrained test and evaluation environment. The results of this study showed that Marshall Space Flight Center (MSFC) Test Stand (TS) 4550 could be made compliant, within reasonable cost and schedule impacts, if safety processes and operational limitations were put in place to meet the safety codes and concerns of the Fire Marshall. Trades were performed with key selection criteria to ensure that appropriate levels of occupant safety are incorporated into test facility design modifications. In preparation for the ground vibration tests that were to be performed on the Ares I launch vehicle, the Ares Flight and Integrated Test Office (FITO) organization evaluated the available test facility options, which included the existing mothballed structural dynamic TS4550 used by Apollo and Shuttle, alternative ground vibration test facilities at other locations, and construction of a new dynamic test stand. After an exhaustive assessment of the alternatives, the results favored modifying the TS4550 because it was the lowest cost option and presented the least schedule risk to the NASA Constellation Program for Ares Integrated Vehicle Ground Vibration Test (IVGVT). As the renovation design plans and drawings were being developed for TS4550, a safety concern was discovered the original design for the construction of the test stand, originally built for the Apollo Program and renovated for the Shuttle Program, was completed before NASA s adoption of the currently imposed safety and building codes per National Fire Protection Association Life Safety Code [NFPA 101] and International Building Codes. The initial FITO assessment of the design changes, required to make TS4550 compliant with current safety and building standards, identified a significant cost increase and schedule impact. An effort was launched to thoroughly evaluate the applicable life safety requirements, examine the context in which they were derived, and determine a means by which the TS4550 modifications could be made within budget and on schedule, while still providing the occupants with appropriate levels of safety.
Askins, Bruce↗
In Space Assembled Telescope (ISAT) Study Preliminary Findings
“When is it advantageous to assemble telescopes in space rather than deploying them from launch vehicle fairings”? This question forms the crux of the objectives of a NASA study we have been conducting in collaboration with colleagues from different NASA centers, industry and academia. In this study, we have engaged a broad cross section of experts from the various fields of optics engineering, that is, telescope design and instrument design, structure and thermal engineering, robotics, launch system engineering, orbital mechanics, integration and testing, astrophysics, and NASA programmatics among others. Initial efforts began with a quick review of the current state of art of the component technologies that contribute towards an in-space assembled telescope. Then, leveraging the collective expertise of the diverse group of experts, we formulated a reference telescope design and attempted to develop a baseline approach to modularize the telescope into components amenable for robotic assembly. The group identified different trades associated with modularization and also developed a set of criteria to discern between the different options as revealed by the trades. Based on the modularization of the telescope, we will assess the impact of various launch vehicles, orbits for assembly and operation, robotic systems and operational approaches, and other related variables. From this, a concept to assemble the reference telescope in space from modular components will be developed. Based on this concept, and definition of the modules, we will develop a mission lifecycle plan for an assembled telescope over different phases of preliminary design, detailed design, assembly-test-and-integration, and in space operations. The mission lifecycle plan will be used to evaluate cost and risk implications of in-space assembly toward answering our fundamental question of the advantages, if any, of assembling a telescope in space as compared to self-deployment. In this paper, we summarize the objectives of the study, a review of the status of the underlying component technologies, a description of the methodology, including three different multi-day technical interchange meetings (TIMs), summary of findings from the TIMs and other related activities. In addition, a detailed description of the various factors that impact in-space assembly, their interplay and criteria for discerning among them, a preliminary description of the life cycle plan, including the test and integration plan, and initial observations on cost and risk implications will be included in the paper.
Mukherjee, Rudranarayan↗
Development and refinement of test bed simulations
Lewis Research Center of NASA, with support from Rocketdyne, was engaged in non-real time computer simulation effort for the Space Station Freedom Electric Power System (EPS) EASY5, a simulation package, is used as the primary tool for this activity. Early in the design of the EPS, two test beds were set up at Lewis. The Integrated Test Bed (ITB), that combines and upgrades these test beds, is in the planning stage. The test beds are designed to functionally represent many of the components of the EPS and their interconnections. The simulation effort is primarily directed towards these test beds. Model verification is performed using test bed data.
Dravid, Narayan V.↗