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NASA NTRS2011

Component-Level Electronic-Assembly Repair (CLEAR) System Architecture

This document captures the system architecture for a Component-Level Electronic-Assembly Repair (CLEAR) capability needed for electronics maintenance and repair of the Constellation Program (CxP). CLEAR is intended to improve flight system supportability and reduce the mass of spares required to maintain the electronics of human rated spacecraft on long duration missions. By necessity it allows the crew to make repairs that would otherwise be performed by Earth based repair depots. Because of practical knowledge and skill limitations of small spaceflight crews they must be augmented by Earth based support crews and automated repair equipment. This system architecture covers the complete system from ground-user to flight hardware and flight crew and defines an Earth segment and a Space segment. The Earth Segment involves database management, operational planning, and remote equipment programming and validation processes. The Space Segment involves the automated diagnostic, test and repair equipment required for a complete repair process. This document defines three major subsystems including, tele-operations that links the flight hardware to ground support, highly reconfigurable diagnostics and test instruments, and a CLEAR Repair Apparatus that automates the physical repair process.

Oeftering, Richard C.↗

NASA NTRS2011

NEEMO - NASA's Extreme Environment Mission Operations: On to a NEO

During NEEMO missions, a crew of six Aquanauts lives aboard the National Oceanic and Atmospheric Administration (NOAA) Aquarius Underwater Laboratory the world's only undersea laboratory located 5.6 km off shore from Key Largo, Florida. The Aquarius habitat is anchored 62 feet deep on Conch Reef which is a research only zone for coral reef monitoring in the Florida Keys National Marine Sanctuary. The crew lives in saturation for a week to ten days and conducts a variety of undersea EVAs (Extra Vehicular Activities) to test a suite of long-duration spaceflight Engineering, Biomedical, and Geoscience objectives. The crew also tests concepts for future lunar exploration using advanced navigation and communication equipment in support of the Constellation Program planetary exploration analog studies. The Astromaterials Research and Exploration Science (ARES) Directorate and Behavioral Health and Performance (BHP) at NASA/Johnson Space Center (JSC), Houston, Texas support this effort to produce a high-fidelity test-bed for studies of human planetary exploration in extreme environments as well as to develop and test the synergy between human and robotic curation protocols including sample collection, documentation, and sample handling. The geoscience objectives for NEEMO missions reflect the requirements for Lunar Surface Science outlined by the LEAG (Lunar Exploration Analysis Group) and CAPTEM (Curation and Analysis Planning Team for Extraterrestrial Materials) white paper [1]. The BHP objectives are to investigate best meas-ures and tools for assessing decrements in cogni-tive function due to fatigue, test the feasibility study examined how teams perform and interact across two levels, use NEEMO as a testbed for the development, deployment, and evaluation of a scheduling and planning tool. A suite of Space Life Sciences studies are accomplished as well, ranging from behavioral health and performance to immunology, nutrition, and EVA suit design results of which will directly support the investigation of open questions and operational concepts that will enable NASA to continue its plan for planetary exploration.

Bell, M. S.↗

NASA NTRS2009

Modeling and Simulation at NASA

This slide presentation is composed of two topics. The first reviews the use of modeling and simulation (M&S) particularly as it relates to the Constellation program and discrete event simulation (DES). DES is defined as a process and system analysis, through time-based and resource constrained probabilistic simulation models, that provide insight into operation system performance. The DES shows that the cycles for a launch from manufacturing and assembly to launch and recovery is about 45 days and that approximately 4 launches per year are practicable. The second topic reviews a NASA Standard for Modeling and Simulation. The Columbia Accident Investigation Board made some recommendations related to models and simulations. Some of the ideas inherent in the new standard are the documentation of M&S activities, an assessment of the credibility, and reporting to decision makers, which should include the analysis of the results, a statement as to the uncertainty in the results,and the credibility of the results. There is also discussion about verification and validation (V&V) of models. There is also discussion about the different types of models and simulation.

Steele, Martin J.↗

NASA NTRS2011

Overview of the Altair Lunar Lander Thermal Control System Design and the Impacts of Global Access

NASA's Constellation Program (CxP) was developed to successfully return humans to the Lunar surface prior to 2020. The CxP included several different project offices including Altair, which was planned to be the next generation Lunar Lander. The Altair missions were architected to be quite different than the Lunar missions accomplished during the Apollo era. These differences resulted in a significantly dissimilar Thermal Control System (TCS) design. The current paper will summarize the Altair mission architecture and the various operational phases associated with the planned mission. In addition, the derived thermal requirements and the TCS designed to meet these unique and challenging thermal requirements will be presented. During the past year, the design team has focused on developing a vehicle architecture capable of accessing the entire Lunar surface. Due to the widely varying Lunar thermal environment, this global access requirement resulted in major changes to the thermal control system architecture. These changes, and the rationale behind the changes, will be detailed throughout the current paper.

Stephan, Ryan A.↗

NASA NTRS2011

Constellation Commodities Studies Summary

Constellation program was NASA's long-term program for space exploration. The goal of the commodities studies was to solicit industry expertise in production, storage, and transportation required for future use and to improve efficiency and life cycle cost over legacy methods. Objectives were to consolidate KSC, CCAFS and other requirements; extract available industry expertise; identify commercial opportunities; and establish synergy with State of Florida partnerships. Study results are reviewed.

Dirschka, Eric↗

NASA NTRS2011

Constellation Lessons Learned Executive Summary

This slide presentation reviews the lessons learned from the Constellation Program (CxP) and identified several factors that contributed to the inability of the CxP to meet the cost and schedule commitments. The review includes a significant section on the context in which the CxP operated since new programs are likely to experience the same constraints.

Thomas, L. Dale↗

NASA NTRS2011

Injury Potential Testing of Suited Occupants During Dynamic Spacecraft Flight Phases

In support of the NASA Constellation Program, a space-suit architecture was envisioned for support of Launch, Entry, Abort, Micro-g EVA, Post Landing crew operations, and under emergency conditions, survival. This space suit architecture is unique in comparison to previous launch, entry, and abort (LEA) suit architectures in that it utilized rigid mobility elements in the scye and the upper arm regions. The suit architecture also employed rigid thigh disconnect elements to allow for quick disconnect functionality above the knee which allowed for commonality of the lower portion of the suit across two suit configurations. This suit architecture was designed to interface with the Orion seat subsystem, which includes seat components, lateral supports, and restraints. Due to this unique configuration of spacesuit mobility elements, combined with the need to provide occupant protection during dynamic landing events, risks were identified with potential injury due to the suit characteristics described above. To address the risk concerns, a test series was developed to evaluate the likelihood and consequences of these potential issues. Testing included use of Anthropomorphic Test Devices (ATDs), Post Mortem Human Subjects (PMHS), and representative seat/suit hardware in combination with high linear acceleration events. The ensuing treatment focuses on detailed results of the testing that has been conducted under this test series thus far.

McFarland, Shane M.↗

NASA NTRS2011

Ares I-X Flight Data Evaluation: Executive Overview

NASA's Constellation Program (CxP) successfully launched the Ares I-X flight test vehicle on October 28, 2009. The Ares I-X flight was a developmental flight test to demonstrate that this very large, long, and slender vehicle could be controlled successfully. The flight offered a unique opportunity for early engineering data to influence the design and development of the Ares I crew launch vehicle. As the primary customer for flight data from the Ares I-X mission, the Ares Projects Office (APO) established a set of 33 flight evaluation tasks to correlate flight results with prospective design assumptions and models. The flight evaluation tasks used Ares I-X data to partially validate tools and methodologies in technical disciplines that will ultimately influence the design and development of Ares I and future launch vehicles. Included within these tasks were direct comparisons of flight data with preflight predictions and post-flight assessments utilizing models and processes being applied to design and develop Ares I. The benefits of early development flight testing were made evident by results from these flight evaluation tasks. This overview provides summary information from assessment of the Ares I-X flight test data and represents a small subset of the detailed technical results. The Ares Projects Office published a 1,600-plus-page detailed technical report that documents the full set of results. This detailed report is subject to the International Traffic in Arms Regulations (ITAR) and is available in the Ares Projects Office archives files.

Huebner, Lawrence D.↗

NASA NTRS2010

Ares I-X Flight Test Development Challenges and Success Factors

The NASA Constellation Program's Ares I-X rocket launched successfully on October 28, 2009 collecting valuable data and providing risk reduction for the Ares I project. The Ares I-X mission was formulated and implemented in less than four years commencing with the Exploration Systems Architecture Study in 2005. The test configuration was founded upon assets and processes from other rocket programs including Space Shuttle, Atlas, and Peacekeeper. For example, the test vehicle's propulsion element was a Shuttle Solid Rocket Motor. The Ares I-X rocket comprised a motor assembly, mass and outer mold line simulators of the Ares I Upper Stage, Orion Spacecraft and Launch Abort System, a roll control system, avionics, and other miscellaneous components. The vehicle was 327 feet tall and weighed approximately 1,800,000 pounds. During flight the rocket reached a maximum speed of Mach 4.8 and an altitude of 150,000 feet. The vehicle demonstrated staging at 130,000 feet, tested parachutes for recovery of the motor, and utilized approximately 900 sensors for data collection. Developing a new launch system and preparing for a safe flight presented many challenges. Specific challenges included designing a system to withstand the environments, manufacturing large structures, and re-qualifying heritage hardware. These and other challenges, if not mitigated, may have resulted in test cancellation. Ares I-X succeeded because the mission was founded on carefully derived objectives, led by decisive and flexible management, implemented by an exceptionally talented and dedicated workforce, and supported by a thorough independent review team. Other major success factors include the use of proven heritage hardware, a robust System Integration Laboratory, multi-NASA center and contractor team, concurrent operations, efficient vehicle assembly, effective risk management, and decentralized element development with a centralized control board. Ares I-X was a technically complex test that required creative thinking, risk taking, and a passion to succeed.

Askins, Bruce↗

NASA NTRS2011

Ares I-X Test Flight Reference Trajectory Development

Ares I-X was the first test flight of NASA's Constellation Program's Ares I crew launch vehicle. Ares I is a two stage to orbit launch vehicle that provides crew access to low Earth orbit for NASA's future manned exploration missions. The Ares I first stage consists of a Shuttle solid rocket motor (SRM) modified to include an additional propellant segment and a liquid propellant upper stage with an Apollo J2X engine modified to increase its thrust capability. The modified propulsion systems were not available for the first test flight, thus the test had to be conducted with an existing Shuttle 4 segment reusable solid rocket motor (RSRM) and an inert Upper Stage. The test flight's primary objective was to demonstrate controllability of an Ares I vehicle during first stage boost and the ability to perform a successful separation. In order to demonstrate controllability, the Ares I-X ascent control algorithms had to maintain stable flight throughout a flight environment equivalent to Ares I. The goal of the test flight reference trajectory development was to design a boost trajectory using the existing RSRM that results in a flight environment equivalent to Ares I. A trajectory similarity metric was defined as the integrated difference between the Ares I and Ares I-X Mach versus dynamic pressure relationships. Optimization analyses were performed that minimized the metric by adjusting the inert upper stage weight and the ascent steering profile. The sensitivity of the optimal upper stage weight and steering profile to launch month was also investigated. A response surface approach was used to verify the optimization results. The analyses successfully defined monthly ascent trajectories that matched the Ares I reference trajectory dynamic pressure versus Mach number relationship to within 10% through Mach 3.5. The upper stage weight required to achieve the match was found to be feasible and varied less than 5% throughout the year. The paper will discuss the flight test requirements, provide Ares I-X vehicle background, discuss the optimization analyses used to meet the requirements, present analysis results, and compare the reference trajectory to the reconstructed flight trajectory.

Starr, Brett R.↗

NASA NTRS2011

Ares I-X Malfunction Turn Range Safety Analysis

Ares I-X was the designation given to the flight test version of the Ares I rocket which was developed by NASA (also known as the Crew Launch Vehicle (CLV) component of the Constellation Program). The Ares I-X flight test vehicle achieved a successful flight test on October 28, 2009, from Pad LC-39B at Kennedy Space Center, Florida (KSC). As part of the flight plan approval for the test vehicle, a range safety malfunction turn analysis was performed to support the risk assessment and vehicle destruct criteria development processes. Several vehicle failure scenarios were identified which could have caused the vehicle trajectory to deviate from its normal flight path. The effects of these failures were evaluated with an Ares I-X 6 degrees-of-freedom (6-DOF) digital simulation, using the Program to Optimize Simulated Trajectories Version II (POST2) simulation tool. The Ares I-X simulation analysis provided output files containing vehicle trajectory state information. These were used by other risk assessment and vehicle debris trajectory simulation tools to determine the risk to personnel and facilities in the vicinity of the launch area at KSC, and to develop the vehicle destruct criteria used by the flight test range safety officer in the event of a flight test anomaly of the vehicle. The simulation analysis approach used for this study is described, including descriptions of the failure modes which were considered and the underlying assumptions and ground rules of the study.

Beaty, J. R.↗

NASA NTRS2010

Orion Abort Flight Test

The purpose of NASA's Constellation project is to create the new generation of spacecraft for human flight to the International Space Station in low-earth orbit, the lunar surface, as well as for use in future deep-space exploration. One portion of the Constellation program was the development of the Orion crew exploration vehicle (CEV) to be used in spaceflight. The Orion spacecraft consists of a crew module, service module, space adapter and launch abort system. The crew module was designed to hold as many as six crew members. The Orion crew exploration vehicle is similar in design to the Apollo space capsules, although larger and more massive. The Flight Test Office is the responsible flight test organization for the launch abort system on the Orion crew exploration vehicle. The Flight Test Office originally proposed six tests that would demonstrate the use of the launch abort system. These flight tests were to be performed at the White Sands Missile Range in New Mexico and were similar in nature to the Apollo Little Joe II tests performed in the 1960s. The first flight test of the launch abort system was a pad abort (PA-1), that took place on 6 May 2010 at the White Sands Missile Range in New Mexico. Primary flight test objectives were to demonstrate the capability of the launch abort system to propel the crew module a safe distance away from a launch vehicle during a pad abort, to demonstrate the stability and control characteristics of the vehicle, and to determine the performance of the motors contained within the launch abort system. The focus of the PA-1 flight test was engineering development and data acquisition, not certification. In this presentation, a high level overview of the PA-1 vehicle is given, along with an overview of the Mobile Operations Facility and information on the White Sands tracking sites for radar & optics. Several lessons learned are presented, including detailed information on the lessons learned in the development of wind placards for flight. PA-1 flight data is shown, as well as a comparison of PA-1 flight data to nonlinear simulation Monte Carlo data.

Hayes, Peggy Sue↗

NASA NTRS2011

First Stage Solid Propellant Multiply Debris Thermal Analysis

Destruction of a solid rocket stage of a launch vehicle can create a thermal radiation hazard for an aborting crew module. This hazard was assessed for the Constellation Program (Cx) crew and launch vehicle concept. For this concept, if an abort was initiated in first stage flight, the Crew Module (CM) will separate and be pulled away from the malfunctioning launch vehicle via a Launch Abort System (LAS). Having aborted the mission, the launch vehicle will likely be destroyed via a Flight Termination System (FTS) in order to prevent it from errantly traversing back over land and posing a risk to the public. The resulting launch vehicle debris field, composed primarily of first stage solid propellant, poses a threat to the CM. The harsh radiative thermal environment, caused by surrounding burning propellant debris, may lead to CM parachute failure. A methodology, detailed herein, has been developed to address this concern and to quantify the risk of first stage propellant debris leading to the thermal demise of the CM parachutes. Utilizing basic thermal radiation principles, a software program was developed to calculate parachute temperature as a function of time for a given abort trajectory and debris piece trajectory set. Two test cases, considered worst case aborts with regard to launch vehicle debris environments, were analyzed using the simulation: an abort declared at Mach 1 and an abort declared at maximum dynamic pressure (Max Q). For both cases, the resulting temperature profiles indicated that thermal limits for the parachutes were not exceeded. However, short duration close encounters by single debris pieces did have a significant effect on parachute temperature. Therefore while these two test cases did not indicate exceedance of thermal limits, in order to quantify the risk of parachute failure due to radiative effects from the abort environment, a more thorough probability-based analysis using the methodology demonstrated herein must be performed.

Toleman, Benjamin M.↗

NASA NTRS2008

Workshop Report on Ares V Solar System Science

The workshop blended three major themes: (1) How can elements of the Constellation program, and specifically, the planned Ares-V heavy-launch vehicle, benefit the planetary community by enabling the launch of large planetary payloads that cannot be launched on existing vehicles, and how can the capabilities of an Ares V allow the planetary community to redesign missions to achieve lower risk, and perhaps lower cost on these missions? (2) What are some of the planetary missions that either can be significantly enhanced or enabled by an Ares-V launch vehicle? What constraints do these mission concepts place on the payload environment of the Ares V? (3) Technology challenges that need to be addressed for launching large planetary payloads. Presentations varied in length from 15-40 minutes. Ample time was provided for discussion.

Langhoff, Stephanie↗

NASA NTRS2011

Technology Applications that Support Space Exploration

Several enabling technologies have been identified that would provide significant benefits for future space exploration. In-Space demonstrations should be chosen so that these technologies will have a timely opportunity to improve efficiencies and reduce risks for future spaceflight. An early window exists to conduct ground and flight demonstrations that make use of existing assets that were developed for the Space Shuttle and the Constellation programs. The work could be mostly performed using residual program civil servants, existing facilities and current commercial launch capabilities. Partnering these abilities with the emerging commercial sector, along with other government agencies, academia and with international partners would provide an affordable and timely approach to get the launch costs down for these payloads, while increasing the derived benefits to a larger community. There is a wide scope of varied technologies that are being considered to help future space exploration. However, the cost and schedule would be prohibitive to demonstrate all these in the near term. Determining which technologies would yield the best return in meeting our future space needs is critical to building an achievable Space Architecture that allows exploration beyond Low Earth Orbit. The best mix of technologies is clearly to be based on our future needs, but also must take into account the availability of existing assets and supporting partners. Selecting those technologies that have complimentary applications will provide the most knowledge, with reasonable cost, for future use The plan is to develop those applications that not only mature the technology but actually perform a useful task or mission. These might include such functions as satellite servicing, a propulsion stage, processing lunar regolith, generating and transmitting solar power, cryogenic fluid transfer and storage and artificial gravity. Applications have been selected for assessment for future consideration and are addressed in this paper. These applications have been made available to the various NASA study groups that are determining the next steps the Agency must take to secure a sound foundation for future space exploration The paper also addresses how follow-on demonstrations, as launch performance grows, can build on the earlier applications to provide increased benefits for both the commercial and scientific communities. The architecture of incrementally building upon previous successes and insights dramatically lowers the overall associated risk for developing and maturing the key enabling technologies. The goal is to establish a potential business case that encourages commercial activity, thereby reducing the cost for the demonstration while using the technology maturation in developing readiness for future space exploration with overall less risk.

Henderson, Edward M.↗

NASA NTRS2011

Achieving the Proper Balance Between Crew and Public Safety

A paramount objective of all human-rated launch and reentry vehicle developers is to ensure that the risks to both the crew onboard and the public are minimized within reasonable cost, schedule, and technical constraints. Past experience has shown that proper attention to range safety requirements necessary to ensure public safety must be given early in the design phase to avoid additional operational complexities or threats to the safety of people onboard, and the design engineers must give these requirements the same consideration as crew safety requirements. For human spaceflight, the primary purpose and operational concept for any flight safety system is to protect the public while maximizing the likelihood of crew survival. This paper will outline the policy considerations, technical issues, and operational impacts regarding launch and reentry vehicle failure scenarios where crew and public safety are intertwined and thus addressed optimally in an integrated manner. An overview of existing range and crew safety policy requirements will be presented. Application of these requirements and lessons learned from both the Space Shuttle and Constellation Programs will also be discussed. Using these past programs as examples, the paper will detail operational, design, and analysis approaches to mitigate and balance the risks to people onboard and in the public. Manned vehicle perspectives from the Federal Aviation Administration (FAA) and Air Force organizations that oversee public safety will be summarized as well. Finally, the paper will emphasize the need to factor policy, operational, and analysis considerations into the early design trades of new vehicles to help ensure that both crew and public safety are maximized to the greatest extent possible.

Gowan, John↗

NASA NTRS2011

Orion Crew Module Aerodynamic Testing

The Apollo-derived Orion Crew Exploration Vehicle (CEV), part of NASA s now-cancelled Constellation Program, has become the reference design for the new Multi-Purpose Crew Vehicle (MPCV). The MPCV will serve as the exploration vehicle for all near-term human space missions. A strategic wind-tunnel test program has been executed at numerous facilities throughout the country to support several phases of aerodynamic database development for the Orion spacecraft. This paper presents a summary of the experimental static aerodynamic data collected to-date for the Orion Crew Module (CM) capsule. The test program described herein involved personnel and resources from NASA Langley Research Center, NASA Ames Research Center, NASA Johnson Space Flight Center, Arnold Engineering and Development Center, Lockheed Martin Space Sciences, and Orbital Sciences. Data has been compiled from eight different wind tunnel tests in the CEV Aerosciences Program. Comparisons are made as appropriate to highlight effects of angle of attack, Mach number, Reynolds number, and model support system effects.

Murphy, Kelly J.↗

NASA NTRS2011

Contributions of TetrUSS to Project Orion

The NASA Constellation program has relied heavily on Computational Fluid Dynamics simulations for generating aerodynamic databases and design loads. The Orion Project focuses on the Orion Crew Module and the Orion Launch Abort Vehicle. NASA TetrUSS codes (GridTool/VGRID/USM3D) have been applied in a supporting role to the Crew Exploration Vehicle Aerosciences Project for investigating various aerodynamic sensitivities and supplementing the aerodynamic database. This paper provides an overview of the contributions from the TetrUSS team to the Project Orion Crew Module and Launch Abort Vehicle aerodynamics, along with selected examples to highlight the challenges encountered along the way. A brief description of geometries and tasks will be discussed followed by a description of the flow solution process that produced production level computational solutions. Four tasks conducted by the USM3D team will be discussed to show how USM3D provided aerodynamic data for inclusion in the Orion aero-database, contributed data for the build-up of aerodynamic uncertainties for the aero-database, and provided insight into the flow features about the Crew Module and the Launch Abort Vehicle.

Mcmillin, Susan N.↗