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NASA NTRS2013

Reconstruction of Orion Engineering Development Unit (EDU) Parachute Inflation Loads

The process of reconstructing inflation loads of Capsule Parachute Assembly System (CPAS) has been updated as the program transitioned to testing Engineering Development Unit (EDU) hardware. The equations used to reduce the test data have been re-derived based on the same physical assumptions made by simulations. Due to instrumentation challenges, individual parachute loads are determined from complementary accelerometer and load cell measurements. Cluster inflations are now simulated by modeling each parachute individually to better represent different inflation times and non-synchronous disreefing. The reconstruction procedure is tailored to either infinite mass or finite mass events based on measurable characteristics from the test data. Inflation parameters are determined from an automated optimization routine to reduce subjectivity. Infinite mass inflation parameters have been re-defined to avoid unrealistic interactions in Monte Carlo simulations. Sample cases demonstrate how best-fit inflation parameters are used to generate simulated drag areas and loads which favorably agree with test data.

Ray, Eric S.↗
NASA NTRS1995

Research and technology 1995 annual report

As the NASA Center responsible for assembly, checkout, servicing, launch, recovery, and operational support of Space Transportation System elements and payloads, the John F. Kennedy Space Center is placing increasing emphasis on its advanced technology development program. This program encompasses the efforts of the Engineering Development Directorate laboratories, most of the KSC operations contractors, academia, and selected commercial industries - all working in a team effort within their own areas of expertise. This edition of the Kennedy Space Center Research and Technology 1995 Annual Report covers efforts of all these contributors to the KSC advanced technology development program, as well as technology transfer activities. Major areas of research include environmental engineering, automation, robotics, advanced software, materials science, life sciences, mechanical engineering, nondestructive evaluation, and industrial engineering.

Source record↗
NASA NTRS2012

Phase Function Determination in Support of Orbital Debris Size Estimation

To recover the size of a space debris object from photometric measurements, it is necessary to determine its albedo and basic shape: if the albedo is known, the reflective area can be calculated; and if the shape is known, the shape and area taken together can be used to estimate a characteristic dimension. Albedo is typically determined by inferring the object s material type from filter photometry or spectroscopy and is not the subject of the present study. Object shape, on the other hand, can be revealed from a time-history of the object s brightness response. The most data-rich presentation is a continuous light-curve that records the object s brightness for an entire sensor pass, which could last for tens of minutes to several hours: from this one can see both short-term periodic behavior as well as brightness variations with phase angle. Light-curve interpretation, however, is more art than science and does not lend itself easily to automation; and the collection method, which requires single-object telescope dedication for long periods of time, is not well suited to debris survey conditions. So one is led to investigate how easily an object s brightness phase function, which can be constructed from the more survey-friendly point photometry, can be used to recover object shape. Such a recovery is usually attempted by comparing a phase-function curve constructed from an object s empirical brightness measurements to analytically-derived curves for basic shapes or shape combinations. There are two ways to accomplish this: a simple averaged brightness-versus phase curve assembled from the empirical data, or a more elaborate approach in which one is essentially calculating a brightness PDF for each phase angle bin (a technique explored in unpublished AFRL/RV research and in Ojakangas 2011); in each case the empirical curve is compared to analytical results for shapes of interest. The latter technique promises more discrimination power but requires more data; the former can be assembled in its essentials from fewer measurements but will be less definitive in its assignments. The goal of the present study is to evaluate both techniques under debris survey conditions to determine their relative performance and, additionally, to learn precisely how a survey should be conducted in order to maximize their performance. Because the distendedness of objects has more of an effect than their precise shape in calculating a characteristic dimension, one is interested in the techniques discrimination ability to distinguish between an elongated rectangular prism and a short rectangular prism or cube, or an elongated cylinder from a squat cylinder or sphere. Sensitivity studies using simulated data will be conducted to determine discrimination power for both techniques as a function of amount of data collected and range (and specific region) of phase angles sampled. Empirical GEODSS photometry data for distended objects (dead payloads with solar panels, rocket bodies) and compact objects (cubesats, calibration spheres, squat payloads) will also be used to test this discrimination ability. The result will be a recommended technique and data collection paradigm for debris surveys in order to maximize this type of discrimination.

Hejduk, M. D.↗
NASA NTRS2004

Automating Traceability for Generated Software Artifacts

Program synthesis automatically derives programs from specifications of their behavior. One advantage of program synthesis, as opposed to manual coding, is that there is a direct link between the specification and the derived program. This link is, however, not very fine-grained: it can be best characterized as Program is-derived- from Specification. When the generated program needs to be understood or modified, more $ne-grained linking is useful. In this paper, we present a novel technique for automatically deriving traceability relations between parts of a specification and parts of the synthesized program. The technique is very lightweight and works -- with varying degrees of success - for any process in which one artifact is automatically derived from another. We illustrate the generality of the technique by applying it to two kinds of automatic generation: synthesis of Kalman Filter programs from speci3cations using the Aut- oFilter program synthesis system, and generation of assembly language programs from C source code using the GCC C compilel: We evaluate the effectiveness of the technique in the latter application.

Richardson, Julian↗
NASA NTRS2012

LU60645GT and MA132843GT Catalogues of Lunar and Martian Impact Craters Developed Using a Crater Shape-based Interpolation Crater Detection Algorithm for Topography Data

For Mars, 57,633 craters from the manually assembled catalogues and 72,668 additional craters identified using several crater detection algorithms (CDAs) have been merged into the MA130301GT catalogue. By contrast, for the Moon the most complete previous catalogue contains only 14,923 craters. Two recent missions provided higher-quality digital elevation maps (DEMs): SELENE (in 1/16° resolution) and Lunar Reconnaissance Orbiter (we used up to 1/512°). This was the main motivation for work on the new Crater Shape-based interpolation module, which improves previous CDA as follows: (1) it decreases the number of false-detections for the required number of true detections; (2) it improves detection capabilities for very small craters; and (3) it provides more accurate automated measurements of craters' properties. The results are: (1) LU60645GT, which is currently the most complete (up to ∼D>=8 km) catalogue of Lunar craters; and (2) MA132843GT catalogue of Martian craters complete up to ∼D>=2 km, which is the extension of the previous MA130301GT catalogue. As previously achieved for Mars, LU60645GT provides all properties that were provided by the previous Lunar catalogues, plus: (1) correlation between morphological descriptors from used catalogues; (2) correlation between manually assigned attributes and automated measurements; (3) average errors and their standard deviations for manually and automatically assigned attributes such as position coordinates, diameter, depth/diameter ratio, etc; and (4) a review of positional accuracy of used datasets. Additionally, surface dating could potentially be improved with the exhaustiveness of this new catalogue. The accompanying results are: (1) the possibility of comparing a large number of Lunar and Martian craters, of e.g. depth/diameter ratio and 2D profiles; (2) utilisation of a method for re-projection of datasets and catalogues, which is very useful for craters that are very close to poles; and (3) the extension of the previous framework for evaluation of CDAs with datasets and ground-truth catalogue for the Moon.

Craters↗
NASA NTRS1991

A PARC system for terminal docking

A Panoramic viewing system for Automated Rendezvous and Capture (PARC) has been proposed as a visual information feedback system for terminal docking/berthing. The system relies on a unique Panoramic Annular Lens (PAL) which captures an image of its surroundings in real time. This paper describes the evolution of the PAL along with technical details of its imaging capabilities. Several examples are given of radial metrology, where PAL imaging systems are used to perform visual inspections and measurements. Digital image acquisition and processing techniques, used to interpret various features appearing in the images and to transform images for improved human viewing, are also included. These discussions are followed by a potential application for PARC involving berthing of active and passive mechanical assemblies associated with Space Station Freedom.

Gilbert, John A.↗
NASA NTRS1977

Microbiological profiles of the Viking spacecraft

Planetary quarantine requirements associated with the launch of two Viking spacecraft necessitated microbiological assessment during assembly and testing at Cape Canaveral and the Kennedy Space Center. Samples were collected from the Viking Lander Capsules (VLC), Orbiters (VO), and Shrouds at predetermined intervals during assembly and testing. Levels of bacterial spores per square meter on the VLC-1 and VLC-2 were 1.6 x 10 squared and 9.7, respectively, prior to dry-heat sterilization. The ranges of aerobic mesophilic microorganisms detected on the VO-1 and VO-2 were 4.2 x 10 squared to 4.3 x 10 cubed and 2.3 x 10 squared to 8.9 x 10 cubed/sq m, respectively. Approximately 1300 colonies were picked from culture plates, identified, lyophilized, and stored for future reference. About 75% of all isolates were microorganisms considered indigenous to humans; the remaining isolates were associated with soil and dust. The percentage of microorganisms of human origin was consistent with results obtained with previous automated spacecraft but slightly lower than those observed for manned (Apollo) spacecraft.

Puleo, J. R.↗
NASA NTRS1994

Flexible manufacturing for photonics device assembly

The assembly of photonics devices such as laser diodes, optical modulators, and opto-electronics multi-chip modules (OEMCM), usually requires the placement of micron size devices such as laser diodes, and sub-micron precision attachment between optical fibers and diodes or waveguide modulators (usually referred to as pigtailing). This is a very labor intensive process. Studies done by the opto-electronics (OE) industry have shown that 95 percent of the cost of a pigtailed photonic device is due to the use of manual alignment and bonding techniques, which is the current practice in industry. At Lawrence Livermore National Laboratory, we are working to reduce the cost of packaging OE devices through the use of automation. Our efforts are concentrated on several areas that are directly related to an automated process. This paper will focus on our progress in two of those areas, in particular, an automated fiber pigtailing machine and silicon micro-technology compatible with an automated process.

Lu, Shin-Yee↗
NASA NTRS1997

Advanced Technology Composite Fuselage - Manufacturing

The goal of Boeing's Advanced Technology Composite Aircraft Structures (ATCAS) program is to develop the technology required for cost-and weight-efficient use of composite materials in transport fuselage structure. Carbon fiber reinforced epoxy was chosen for fuselage skins and stiffening elements, and for passenger and cargo floor structures. The automated fiber placement (AFP) process was selected for fabrication of stringer-stiffened and sandwich skin panels. Circumferential and window frames were braided and resin transfer molded (RTM'd). Pultrusion was selected for fabrication of floor beams and constant-section stiffening elements. Drape forming was chosen for stringers and other stiffening elements cocured to skin structures. Significant process development efforts included AFP, braiding, RTM, autoclave cure, and core blanket fabrication for both sandwich and stiffened-skin structure. Outer-mold-line and inner-mold-line tooling was developed for sandwich structures and stiffened-skin structure. The effect of design details, process control and tool design on repeatable, dimensionally stable, structure for low cost barrel assembly was assessed. Subcomponent panels representative of crown, keel, and side quadrant panels were fabricated to assess scale-up effects and manufacturing anomalies for full-scale structures. Manufacturing database including time studies, part quality, and manufacturing plans were generated to support the development of designs and analytical models to access cost, structural performance, and dimensional tolerance.

Wilden, K. S.↗
NASA NTRS1989

Traction-drive force transmission for telerobotic joints

The U.S. Space Station Program is providing many technological developments to meet the increasing demands of designing such a facility. One of the key areas of research is that of telerobotics for space station assembly and maintenance. Initial implementation will be teleoperated, but long-term plans call for autonomous robotics. One of the essential components for making this transition successful is the manipulator joints mechanism. Historically, teleoperated manipulators and industrial robotics have had very different mechanisms for force transmission. This is because the design objectives are almost mutually exclusive. A teleoperator must have very low friction and inertia to minimize operator fatigue; backlash and stiffness are of secondary concern. A robot, however, must have minimum backlash, and high stiffness for accurate and rapid positioning. A joint mechanism has yet to be developed that can optimize these divergent performance objectives. A joint mechanism that approaches this optimal performance was developed for NASA Langley, Automation Technology Branch. It is a traction-drive differential that uses variable preload mechanisms. The differential provides compact, dexterous motion range with a torque density similar to geared systems. The traction drive offers high stiffness and zero backlash, for good robotic performance, and the variable loading mechanism (VLM) minimizes the drive-train friction, for improved teleoperation.

Kuban, D. P.↗
NASA NTRS2020

Assembly and Integration Process of the High-Density Detector Array Readout Modules for the Simons Observatory

The Simons Observatory will measure the cosmic microwave background tempera-ture and polarization using a suite of new telescopes in the Atacama Desert in Chile. The Simons Observatory will use dichroic transition edge sensor (TES) bolometer arrays spanning six frequency bands from 27 to 280 GHz. The Simons Observa-tory will pioneer the use of a densely packed multiplexing architecture based on the microwave SQUID multiplexer ( 𝜇mux), housing ∼2000 microwave resonators, each coupled to a TES. The Simons Observatory aims to multiplex each array of ∼2000 detectors with a single pair of coaxial cables and requires a multiplexing factor of ∼1000 . The Simons Observatory cryogenic readout system is called the universal microwave multiplexing module (UMM). The UMM couples to both horn and lenslet-coupled detector arrays and is integrated into the universal focal-plane module (UFM) after being independently characterized. We present processes we have developed for highly repeatable and automated integration methods of UMMs, which will be needed for the production of the 49 UFMs required for the first stage of the Simons Observatory.

CMB↗
NASA NTRS2018

Air Traffic Management Technology Demonstration - 3 (ATD-3) Dynamic Weather Routes Domestic En Route Concept of Operations Synopsis Version 1.0

NASA conducted a survey in 2015 of stakeholders in industry, flight operators, and others to collect data on the most pressing air traffic management (ATM) issues impacting en route operations. Weather related delays and interruptions were identified as the most significant and costly problem impacting en route operations in today's system. Additionally, future traffic demands will place greater demands on the FAA's air traffic control system, necessitate a more efficient and integrated traffic management system and provide controller tools to leverage human productivity. Consequently, NASA is assembling a suite of integrated ground and aircraft-based technologies and decision-making aids under the Airspace Technology Demonstrations 3 (ATD-3) project to continuously search for more efficient weather-avoidance routes and to rapidly respond to weather changes and associated traffic management initiatives. These route efficiency enhancements are targeted at en route airspace and will enable continued use of en route and arrival metering in the presence of weather. NASA's Dynamic Weather Routes (DWR) concept represents a subset of those technologies and focuses primarily on the cruise phase of flight. It leverages existing air traffic weather, airspace, and traffic data, as well as improvements in navigation, surveillance, communication and digital network technologies, and builds upon existing ATM automation to address the shortcomings associated with strategic traffic flow management initiatives and weather forecasting uncertainties. The potential benefits in the form of time, fuel, and cost savings are significant. This concept of operations synopsis provides a detailed description of DWR, its potential benefits and notional implementation paths.

DWR↗
NASA NTRS1995

NASA Tech Briefs, November 1995

The contents include: 1) Mission Accomplished; 2) Resource Report: Marshall Space Flight Center; 3) NASA 1995 Software of the Year Award; 4) Microbolometers Based on Epitaxial YBa2Cu3O(sub 7-x) Thin Films; 5) Garnet Random-Access Memory; 6) Fabrication of SNS Weak Links on SOS Substrates; 7) High-Voltage MOSFET Switching Circuit; 8) Asymmetric Switching for a PWM H-Bridge Power Circuit; 9) Better Ohmic Contacts for InP Semiconductor Devices; 10) Low-Bandgap Thermovoltaic Materials and Devices; 11) Digital Frequency-Differencing Circuit; 12) Imaging Magnetometer; 13) Computer-Assisted Monitoring of a Complex System; 14) Buffered Telemetry Demodulator; 15) Compact Multifunction Inspection Head; 16) Optical Detection of Fractures in Ceramic Diaphragms; 17) Eddy-Current Detection of Cracks in Reinforced Carbon/Carbon; 18) Apparent Thermal Conductivity of Multilayer Insulation; 19) Optimizing Misch-Metal Compositions in Metal Hydride Anodes; 20) Device for Sampling Surface Contamination; 21) Probabilistic Failure Assessment for Fatigue; 22) Probabilistic Fatigue and Flaw-Propagation Analysis; 23) Windows Program for Driving the TDU-850 Printer; 24) Subband/Transform MATLAB Functions for Processing Images; 25) Computing Equilibrium Chemical Compositions; 26) Program Processes Thermocouple Readings; 27) ICAN-Second-Generation Integrated Composite Analyzer; 28) Integrated Composite Analyzer with Damping Capabilities; 29) Computing Efficiency of Transfer of Microwave Power; 30) Program Calculates Power Demands of Electronic Designs; 31) Cost-Estimation Program; 32) Program Estimates Areas Required by Electronic Designs; 33) Program to Balance Mapped Turbopump Assemblies; 34) BiblioTech; 35) Controlling Mirror Tilt With a Bimorph Actuator; 36) Burst-Disk Device Simulates Effect of Pyrotechnic Device; 37) Bearing-Mounting Concept Accommodates Thermal Expansion; 38) Parallel-Plate Acoustic Absorbers for Hot Environments; 39) Adjustable-Length Strut Withstands Large Cyclic Loads; 40) Tool Indicates Contact Angles in Bearing Raceways; 41) Gravity Slides With Magnetic Braking; 42) High-Torque, Lightweight, Pneumatically Driven Wrench for Small Spaces; 43) Device for Testing Compatibility of an O-Ring; 44) Magnetic Heat Pump Containing Flow Diverters; 45) Variable-Tilt Helicopter Rotor Mast; 46) "Beach-Ball" Robotic Rovers; 47) Apparatus Would Measure Temperatures of Ball Bearings; 48) Flexible Borescope for Inspecting Ducts; 49) Texturing Copper To Reduce Secondary Emission of Electrons; 50) Automated Laser Cutting in Three Dimensions; 51) Algorithm Helps Monitor Engine Operation; 52) Flexible Revision of Data-Processing Communications; 53) Software for Managing the Use of Land; 54) Thermal Strap Increases Cryocooling Efficiency; 55) Reversible Nut With Engagement Indication; 56) Control Algorithms for Kinematically Redundant Manipulators; 57) Computed Hydrogen-Flow Splits in a Rocket Engine; 58) Pressure and Thermal Modeling of Rocket Launches; 59) Field of View of a Spacecraft Antenna: Analysis and Software; 60) Digital Controller for Laser-Beam-Steering Subsystem; 61) More About Beam-Steering Subsystem for Laser Communication; 62) Digital Controller for Laser-Beam-Steering Subsystem: Part 2; 63) Interface Circuit Board for Space-Shuttle Communications; 64) Automated Planning of Spacecraft Telecommunications; 65) Artifacts of Spectral Analysis of Instrument Readings; 66) Neural-Network Controller for Vibration Suppression; 67) Adaptive Finite-Element Computation in Fracture Mechanics; 68) Attitude Control for the Cassini Spacecraft; 69) Analytical Model for Fluid Dynamics in a Microgravity Environment; 70) Study of Rocket-Engine Joints Bonded by NVCU/NARloy-Z; 71) Improved Silicon Nitride for Advanced Heat Engines; 72) Parameters for Welding Aluminum/Lithium Alloys; 73) Lightweight Composite Intertank Structure; 74) Foil Patches Seal Small Vacuum Leaks; 75) Data Base on Cables and Connectors; 76) Effect of Clock Mode on Radiation Hardnessf an ADC; and 77) Fault-Tolerant Control for a Robotic Inspection System.

Source record↗
NASA NTRS2004

Space Technology 5: Pathfinder for Future Micro-Sat Constellations

The Space Technology 5 (ST-5) Project, currently in the implementation phase, is part of the National Aeronautics and Space Administration (NASA) s New Millennium Program (NMP). ST-5 will consist of a constellation of three miniature satellites, each with mass less than 25 kg and size approximately 60 cm by 30 cm. ST-5 addresses technology challenges, as well as fabrication, assembly, test and operations strategies for future micro-satellite missions. ST-5 will be deployed into a highly eccentric, geo-transfer orbit (GTO). This will expose the spacecraft to a high radiation environment as well as provide a low level magnetic background. A three-month flight demonstration phase is planned to validate the technologies and demonstrate concepts for future missions. Each ST-5 spacecraft incorporates NMP competitively-selected breakthrough technologies. These include Cold Gas Micro-Thrusters for propulsion and attitude control, miniature X-band transponder for space-ground communications, Variable Emittance Coatings for dynamic thermal control, and CULPRiT ultra low power logic chip used for Reed-Solomon encoding. The ST-5 spacecraft itself is a technology that can be infused into future missions. It is a fully functional micro-spacecraft built within tight volume and mass constraints. It is built to withstand a high radiation environment, large thermal variations, and high launch loads. The spacecraft power system is low-power and low-voltage, and is designed to turn on after separation &om the launch vehicle. Some of the innovations that are included in the ST-5 design are a custom spacecraft deployment structure, magnetometer deployment boom, nutation damper, X-band antenna, miniature spinning sun sensor, solar array with triple junction solar cells, integral card cage assembly containing single card Command and Data Handling and Power System Electronics, miniature magnetometer, and lithium ion battery. ST-5 will demonstrate the ability of a micro satellite to perform research-quality science. Each ST-5 spacecraft will deploy a precision magnetometer to be used both for attitude determination and as a representative science instrument. The spacecraft has been developed with a low magnetic signature to avoid interference with the magnetometer. The spacecraft will be able to detect and respond autonomously to science events, i.e. significant changes in the magnetic field measurements. The three spacecraft will be a pathfinder for future constellation missions. They will be deployed to demonstrate an appropriate geometry for scientific measurements as a constellation. They will be operationally managed as a constellation, demonstrating automation and communication strategies that will be useful for future missions. The technologies and future mission concepts will be validated both on the ground and in space. Technologies will be validated on the ground by a combination of component level and system level testing of the flight hardware in a thermal vacuum environment. In flight, specific validation runs are planned for each of the technologies. Each validation run consists of one or more orbits with a specific validation objective. This paper will describe the ST-5 mission, and the applicability of the NMP technologies, spacecraft, and mission concepts to future missions. It will also discuss the validation approach for the ST-5 technologies and mission concepts.

Carlisle, Candace↗
NASA NTRS2014

Use of Semantic Technology to Create Curated Data Albums

One of the continuing challenges in any Earth science investigation is the discovery and access of useful science content from the increasingly large volumes of Earth science data and related information available online. Current Earth science data systems are designed with the assumption that researchers access data primarily by instrument or geophysical parameter. Those who know exactly the data sets they need can obtain the specific files using these systems. However, in cases where researchers are interested in studying an event of research interest, they must manually assemble a variety of relevant data sets by searching the different distributed data systems. Consequently, there is a need to design and build specialized search and discover tools in Earth science that can filter through large volumes of distributed online data and information and only aggregate the relevant resources needed to support climatology and case studies. This paper presents a specialized search and discovery tool that automatically creates curated Data Albums. The tool was designed to enable key elements of the search process such as dynamic interaction and sense-making. The tool supports dynamic interaction via different modes of interactivity and visual presentation of information. The compilation of information and data into a Data Album is analogous to a shoebox within the sense-making framework. This tool automates most of the tedious information/data gathering tasks for researchers. Data curation by the tool is achieved via an ontology-based, relevancy ranking algorithm that filters out nonrelevant information and data. The curation enables better search results as compared to the simple keyword searches provided by existing data systems in Earth science.

Ramachandran, Rahul↗
NASA NTRS2014

Use of Semantic Technology to Create Curated Data Albums

One of the continuing challenges in any Earth science investigation is the discovery and access of useful science content from the increasingly large volumes of Earth science data and related information available online. Current Earth science data systems are designed with the assumption that researchers access data primarily by instrument or geophysical parameter. Those who know exactly the data sets they need can obtain the specific files using these systems. However, in cases where researchers are interested in studying an event of research interest, they must manually assemble a variety of relevant data sets by searching the different distributed data systems. Consequently, there is a need to design and build specialized search and discovery tools in Earth science that can filter through large volumes of distributed online data and information and only aggregate the relevant resources needed to support climatology and case studies. This paper presents a specialized search and discovery tool that automatically creates curated Data Albums. The tool was designed to enable key elements of the search process such as dynamic interaction and sense-making. The tool supports dynamic interaction via different modes of interactivity and visual presentation of information. The compilation of information and data into a Data Album is analogous to a shoebox within the sense-making framework. This tool automates most of the tedious information/data gathering tasks for researchers. Data curation by the tool is achieved via an ontology-based, relevancy ranking algorithm that filters out non-relevant information and data. The curation enables better search results as compared to the simple keyword searches provided by existing data systems in Earth science.

Ramachandran, Rahul↗
NASA NTRSDate not supplied

Design and Applications of Tethered Spacecraft Simulators

Small, tethered spacecraft, or space tugs, are a promising space capability. They can be deployed on tethers and used for a wide variety of in-space activities; a large portion of which fall under in-space servicing, assembly, manufacturing (ISAM) functions. This includes functions such as structural mating and assembly, servicing, proximity operations, capture, docking, mating, and relocation. However, there is a great deal of work to be done to raise the Technology Readiness Level (TRL) of the capabilities needed to fully realize these capabilities. The Flat Floor Robotics Lab (FFRL) at NASA’s Marshall Spaceflight Center (MSFC) has been working on space tug development for several years. The eponymous floor is 44 by 86 feet, made from a self-leveling epoxy. This creates an extremely smooth surface that air bearings can float on with very little friction, creating a simulation of zero gravity in a two-dimensional plane. The lab has several platforms of various sizes that act as vehicle simulators for testing sensors, control algorithms, mechanisms, etc. One of these platforms is a small spacecraft simulator, which can be tethered to simulate a space tug. In the last several months, the FFRL team has been working with MSFC’s welding group to conduct a laser beam welding demonstration on air bearing platforms. This demo is utilizing a space tug simulator to fly up to a floating weld platform, where two parts are clamped together and laser welded. The space tug simulator has an air bearing to provide float, as well as several actuated air thrusters to provide propulsion and make the simulator maneuverable. Currently, flights of this simulator are completed by a human operator. An RF hand controller sends signals to both actuate and fire three sets of thrusters on the simulator. This makes any maneuvers of the space tug highly subject to human error, and operators must have dedicated practice time before being able to perform maneuvers with any sufficient reliability. For the current laser welding demonstration, human operated performance is sufficient, but future implementations of in-space welding and other ISAM efforts will require higher precision, reliability, and autonomy. MSFC has funded a project that will allow a small team in the FFRL to develop the next generation of space tug simulator, which will be automated. Closed loop control will allow a user to command a position, or set of positions, that the simulator will be able to “fly” to on its own. This Maneuverable Automated Tethered Spacecraft (MATS) simulator will have configurable design, to allow a variety of payloads and mission configurations to be demonstrated on the air bearing floor. This will be an invaluable test bed for low and mid TRL advancement for space tether mission subsystems, such as more advanced demonstrations of in-space welding. Once one MATSS is constructed and demonstrated effectively, several more can be built, enabling more advanced tether missions; Electric Sail test beds, sensor arrays, and other science-enabling missions. This paper will detail the design and test of the FFRL’s MATS simulator, including efforts to establish closed loop control and autonomous capabilities. It will also detail use cases for this technology, and how it will further develop both develop science and exploration missions.

Space Tethers↗
NASA NTRS2024

Advances in Thermoplastic Composites Over Three Decades – A Literature Review

Recently, there has been a renewed interest in thermoplastic composites driven mainly by advances in automation which can lead to significant cost reductions by increasing manufacturing rates while simultaneously reducing the part count and energy consumption relative to the manufacturing of thermoset composites. At the same time, new material systems have been developed and the thermoplastic composites prepreg material quality has improved over time. Additionally, thermoplastic composites have nearly infinite room-temperature shelf life and production scraps can be reused and retired parts can be recycled, providing opportunities for more sustainable operations and downstream markets. These factors have contributed to a strong interest in advancing thermoplastic composites for aerospace, automotive, and other industrial applications. The objective of the present study is to assess the state of the art regarding the maturity and performance of thermoplastic composite materials and to document the advances made in manufacturing and assembly of thermoplastic composite structures. Therefore, more than 200 NASA reports, conference proceedings and journal papers spanning three and a half decades (1986-2022) were reviewed and the findings summarized. The current study, however, is limited in scope with a focus on the application of thermoplastic composites to aircraft structures. Further, the study does not provide a comprehensive assessment of the available literature but rather offers an overview of past and present research being conducted in the field of thermoplastic composites. The information provided may be used to identify gaps and help guide future research and development. In this report, the opportunities offered by the use of thermoplastic composites in general and challenges encountered in particular are presented first. Second, an overview of thermoplastic materials is presented, manufacturing methods are discussed, and new methods for fastener-less assembly such as welding are introduced. Third, tests that have been performed on different levels of the building block, ranging from coupon to structural level, are presented. In particular, fracture toughness results for different thermoplastic composite materials are used to demonstrate their performance compared to state-of-the-art thermoset composites. Fourth, several examples of analyses are discussed including process modelling and progressive damage analysis (PDA). An extensive list of references and appendices with tables support the narrative. Lastly, a brief summary with outlook and recommendations for future research is provided.

composites↗