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NASA NTRSDate not supplied

Laser Beam Welding Benchmark Experiments Performed in Reduced Gravity and Vacuum

Laser beam welding (LBW) is affected by the extreme temperatures, reduced pressure, and reduced gravity present in space environments. Gravity and pressure especially influence its melt pool and solidification dynamics. A compact, modular vacuum chamber adaptable to flight platforms from parabolic to orbital currently hosts an experiment to investigate the combined influence of reduced gravity and pressure on LBW. A swappable cartridge contains a rotating platen on which customizable workpieces can be welded under vacuum, greatly increasing experimental throughput. Instrumentation includes weld and thermal cameras observing the process, thermocouples placed on workpieces, accelerometers, and vacuum sensors. Experimental data gathered during the welding process will be combined with post-flight nondestructive evaluation, metallography, and mechanical testing to provide validation datasets for computational modeling. Phase I of this effort involves a parabolic flight campaign in low gravity while an anticipated Phase II would proceed to in-space demonstration to access extended duration microgravity.

in-space welding↗

NASA NTRS2012

Modular, Autonomous Command and Data Handling Software with Built-In Simulation and Test

The spacecraft system that plays the greatest role throughout the program lifecycle is the Command and Data Handling System (C&DH), along with the associated algorithms and software. The C&DH takes on this role as cost driver because it is the brains of the spacecraft and is the element of the system that is primarily responsible for the integration and interoperability of all spacecraft subsystems. During design and development, many activities associated with mission design, system engineering, and subsystem development result in products that are directly supported by the C&DH, such as interfaces, algorithms, flight software (FSW), and parameter sets. A modular system architecture has been developed that provides a means for rapid spacecraft assembly, test, and integration. This modular C&DH software architecture, which can be targeted and adapted to a wide variety of spacecraft architectures, payloads, and mission requirements, eliminates the current practice of rewriting the spacecraft software and test environment for every mission. This software allows missionspecific software and algorithms to be rapidly integrated and tested, significantly decreasing time involved in the software development cycle. Additionally, the FSW includes an Onboard Dynamic Simulation System (ODySSy) that allows the C&DH software to support rapid integration and test. With this solution, the C&DH software capabilities will encompass all phases of the spacecraft lifecycle. ODySSy is an on-board simulation capability built directly into the FSW that provides dynamic built-in test capabilities as soon as the FSW image is loaded onto the processor. It includes a six-degrees- of-freedom, high-fidelity simulation that allows complete closed-loop and hardware-in-the-loop testing of a spacecraft in a ground processing environment without any additional external stimuli. ODySSy can intercept and modify sensor inputs using mathematical sensor models, and can intercept and respond to actuator commands. ODySSy integration is unique in that it allows testing of actual mission sequences on the flight vehicle while the spacecraft is in various stages of assembly, test, and launch operations all without any external support equipment or simulators. The ODySSy component of the FSW significantly decreases the time required for integration and test by providing an automated, standardized, and modular approach to integrated avionics and component interface and functional verification. ODySSy further provides the capability for on-orbit support in the form of autonomous mission planning and fault protection.

Cuseo, John↗

NASA NTRS1983

Launch processing for Spacelab 1

The final integration of Spacelab payloads with the Shuttle is described. Attention is given to launch processing planning, schedules, quality control, and problem reports and configuration maintenance. Also covered are the integration and checkout of individual and combined experiments, mounting the end cones, attachment of the transfer tunnel, and inclusion of an extra experiments pallet. The entire Spacelab module was subjected to a full systems simulation before deliverance to the Orbiter bay. Modular parts that were transferred from building-to-building were placed in sealed containers filled with a purged atmosphere during transport.

Mcbrayer, R. O.↗

NASA NTRS1987

Solar concentrator advanced development project

A solar dynamic concentrator design developed for use with a solar-thermodynamic power generation module intended for the Space Station is considered. The truss hexagonal panel reflector uses a modular design approach and is flexible in attainable flux profiles and assembly techniques. Preliminary structural, thermal, and optical analysis results are discussed. Accuracy of the surface reflectors should be within 5 mrad rms slope error, resulting in the need for close fabrication tolerances. Significant fabrication issues to be addressed include the facet reflective and protective coating processes and the surface specularity requirements.

Corrigan, Robert D.↗

NASA NTRS2010

HDU Pressurized Excursion Module (PEM) Prototype Systems Integration

The Habitat Demonstration Unit (HDU) project team constructed an analog prototype lunar surface laboratory called the Pressurized Excursion Module (PEM). The prototype unit subsystems were integrated in a short amount of time, utilizing a skunk-works approach that brought together over 20 habitation-related technologies from a variety of NASA centers. This paper describes the system integration strategies and lessons learned, that allowed the PEM to be brought from paper design to working field prototype using a multi-center team. The system integration process included establishment of design standards, negotiation of interfaces between subsystems, and scheduling fit checks and installation activities. A major tool used in integration was a coordinated effort to accurately model all the subsystems using CAD, so that conflicts were identified before physical components came together. Some of the major conclusions showed that up-front modularity that emerged as an artifact of construction, such as the eight 45 degree "pie slices" making up the module whose steel rib edges defined structural mounting and loading points, dictated much of the configurational interfaces between the major subsystems and workstations. Therefore, 'one of the lessons learned included the need to use modularity as a tool for organization in advance, and to work harder to prevent non-critical aspects of the platform from dictating the modularity that may eventually inform the fight system.

Gill, Tracy R.↗

NASA NTRS2011

Fault-Tolerant, Radiation-Hard DSP

Commercial digital signal processors (DSPs) for use in high-speed satellite computers are challenged by the damaging effects of space radiation, mainly single event upsets (SEUs) and single event functional interrupts (SEFIs). Innovations have been developed for mitigating the effects of SEUs and SEFIs, enabling the use of very-highspeed commercial DSPs with improved SEU tolerances. Time-triple modular redundancy (TTMR) is a method of applying traditional triple modular redundancy on a single processor, exploiting the VLIW (very long instruction word) class of parallel processors. TTMR improves SEU rates substantially. SEFIs are solved by a SEFI-hardened core circuit, external to the microprocessor. It monitors the health of the processor, and if a SEFI occurs, forces the processor to return to performance through a series of escalating events. TTMR and hardened-core solutions were developed for both DSPs and reconfigurable field-programmable gate arrays (FPGAs). This includes advancement of TTMR algorithms for DSPs and reconfigurable FPGAs, plus a rad-hard, hardened-core integrated circuit that services both the DSP and FPGA. Additionally, a combined DSP and FPGA board architecture was fully developed into a rad-hard engineering product. This technology enables use of commercial off-the-shelf (COTS) DSPs in computers for satellite and other space applications, allowing rapid deployment at a much lower cost. Traditional rad-hard space computers are very expensive and typically have long lead times. These computers are either based on traditional rad-hard processors, which have extremely low computational performance, or triple modular redundant (TMR) FPGA arrays, which suffer from power and complexity issues. Even more frustrating is that the TMR arrays of FPGAs require a fixed, external rad-hard voting element, thereby causing them to lose much of their reconfiguration capability and in some cases significant speed reduction. The benefits of COTS high-performance signal processing include significant increase in onboard science data processing, enabling orders of magnitude reduction in required communication bandwidth for science data return, orders of magnitude improvement in onboard mission planning and critical decision making, and the ability to rapidly respond to changing mission environments, thus enabling opportunistic science and orders of magnitude reduction in the cost of mission operations through reduction of required staff. Additional benefits of COTS-based, high-performance signal processing include the ability to leverage considerable commercial and academic investments in advanced computing tools, techniques, and infra structure, and the familiarity of the science and IT community with these computing environments.

Czajkowski, David↗

NASA NTRS2002

Robosphere1: Building A Self-Sustaining Robotic Ecology for Mars Exploration

Robotic exploration of Mars has been a "one shot" approach where each surface mission is planned typically with a rover that will perform a series of experiments for a few weeks or months, until the robot becomes unable to operate in the harsh Mars conditions and simply "dies". It would clearly be desirable to have robots on Mars that can last for much longer periods of time, I propose that there is an approach to sustained robotic exploration that can also pave the way to future human presence. The idea is to continue building a robotic infrastructure with every mission we send. The approach is to built a team of modular robots that could repair individual members when they break down. We could "seed" areas of interest with sturdy power stations (solar, chemical) that teams of robots could use to recharge themselves. We could also seed parts and modules the robots could access for self-repair. No mission could really "fail" if we simply keep adding to and maintaining the existing infrastructure. Simply landing a package of parts will be a success. In time we create a loose infrastructure that can be controlled and augmented from earth on a continuing basis, and which could eventually pave the way for human exploration. I propose that we could begin to build this infrastructure from relatively simple modular robots. Imagine 2 "spider-like" robots built out of small modular snap-in pieces, a bin of these pieces and a bin of snap-in end effectors. One of the spiders breaks down, i.e. one of its modules needs to be replaced. The second spider comes to the rescue and helps the first one replace the broken module. Assuming the input of fresh modules, this process can continue indefinetly. Now start separating robotic explorers from robotic "mechanics", start adding, a category of mechanics that are able to fix at least some of the broken modules (and which in turn can be fixed by the original mechanics), The need for a fresh influx of modules is thus reduced. I submit that we could bootstrap a robotic ecology until it needs very little material from earth and can rely mostly on in-situ resources., We can experiment with this concept in an earthbound facility that can also simulate Mars conditions. I propose that we call this facility Robosphere1.

Colombano, Silvano P.↗

NASA NTRS2003

Application of Core Dynamics Modeling to Core-Mantle Interactions

Observations have demonstrated that length of day (LOD) variation on decadal time scales results from exchange of axial angular momentum between the solid mantle and the core. There are in general four core-mantle interaction mechanisms that couple the core and the mantle. Of which, three have been suggested likely the dominant coupling mechanism for the decadal core-mantle angular momentum exchange, namely, gravitational core-mantle coupling arising from density anomalies in the mantle and in the core (including the inner core), the electromagnetic coupling arising from Lorentz force in the electrically conducting lower mantle (e.g. D-layer), and the topographic coupling arising from non-hydrostatic pressure acting on the core-mantle boundary (CMB) topography. In the past decades, most effort has been on estimating the coupling torques from surface geomagnetic observations (kinematic approach), which has provided insights on the core dynamical processes. In the meantime, it also creates questions and concerns on approximations in the studies that may invalidate the corresponding conclusions. The most serious problem is perhaps the approximations that are inconsistent with dynamical processes in the core, such as inconsistencies between the core surface flow beneath the CMB and the CMB topography, and that between the D-layer electric conductivity and the approximations on toroidal field at the CMB. These inconsistencies can only be addressed with numerical core dynamics modeling. In the past few years, we applied our MoSST (Modular, Scalable, Self-consistent and Three-dimensional) core dynamics model to study core-mantle interactions together with geodynamo simulation, aiming at assessing the effect of the dynamical inconsistencies in the kinematic studies on core-mantle coupling torques. We focus on topographic and electromagnetic core-mantle couplings and find that, for the topographic coupling, the consistency between the core flow and the CMB topography is critical for correct evaluation of the coupling torque.

Kuang, Weijia↗

NASA NTRS2012

Archway for Radiation and Micrometeorite Occurrence Resistance

The environmental conditions of the Moon require mitigation if a long-term human presence is to be achieved for extended periods of time. Radiation, micrometeoroid impacts, high-velocity debris, and thermal cycling represent threats to crew, equipment, and facilities. For decades, local regolith has been suggested as a candidate material to use in the construction of protective barriers. A thickness of roughly 3m is sufficient protection from both direct and secondary radiation from cosmic rays and solar protons; this thickness is sufficient to reduce radiation exposure even during solar flares. NASA has previously identified a need for innovations that will support lunar habitats using lightweight structures because the reduction of structural mass translates directly into additional up and down mass capability that would facilitate additional logistics capacity and increased science return for all mission phases. The development of non-pressurized primary structures that have synergy with the development of pressurized structures is also of interest. The use of indigenous or in situ materials is also a well-known and active area of research that could drastically improve the practicality of human exploration beyond low-Earth orbit. The Archway for Radiation and Micrometeorite Occurrence Resistance (ARMOR) concept is a new, multifunctional structure that acts as radiation shielding and micrometeorite impact shielding for long-duration lunar surface protection of humans and equipment. ARMOR uses a combination of native regolith and a deployed membrane jacket to yield a multifunctional structure. ARMOR is a robust and modular system that can be autonomously assembled on-site prior to the first human surface arrival. The system provides protection by holding a sufficiently thick (3 m) archshaped shell of local regolith around a central cavity. The regolith is held in shape by an arch-shaped jacket made of strong but deployable material. No regolith processing is required. During the regolith filling process, an inflatable structure under the arch supports the mass of the regolith, but once regolith filling is complete the catenary arch formed by the regolith and the jacket becomes self-supporting and the inflatable can be deflated and removed. When complete, habitat modules and equipment can be moved into the protected cavity under the arch. ARMOR is a nearterm system that would provide a reliable and robust lightweight structure technology to support large lunar habitats, drastically lower launch mass, and improve efficient volume use, reducing launch costs.

Giersch, Louis R.↗

NASA NTRSDate not supplied

Automated Reconfigurable Mission Adaptive Digital Assembly Systems (ARMADAS): Robotically Assembled Sustainable Lunar Infrastructure

Introduction: The Automated Reconfigurable Mission Adaptive Digital Assembly Systems (ARMADAS) project at NASA Ames Research Center is developing autonomous infrastructure, instrumentation, and spacecraft assembly and manufacturing capabilities for next generation exploration and science missions, with a goal to change the cost scaling of these missions relative to mission size and duration. Using a building-block approach with a 'kit of parts' composed of ultra-light, high-performance mechanical metamaterials, simplified robots leverage the period environment to achieve high levels of autonomy and reliability for in-space and surface assembly of large-scale apertures, solar-arrays, towers, habitats, and other infrastructure. Robots and structure break down into a compact form factor for launch. By leveraging economies of scale and achieving high-packing ratios, ARMADAS technology can revolutionize possible space missions by breaking the tyranny of the launch shroud, decreasing development times, decreasing mission costs for transformative science capability, and providing a scalable and versatile space infrastructure strategy. Capabilities: To date, the ARMADAS project has demonstrated autonomous assembly of large numbers of structural modules into a meters-scale structure in an earth gravity environment. The mechanical performance is on par with conventional space structures, at a fraction of the cost. By using highly repeatable manufacturing processes (injection molding carbon fiber reinforced space-rated polymers), the structures are both cost effective and highly precise. The ARAMADAS system carefully designs parts for high-precision assembly–the simple and cost-effective robots build structures much larger and more precise than themselves. While maintaining structural efficiency, the ARMADAS system encompasses many functional module types, including for solar power, comm/power routing, etc., that will enable entire infrastructure systems to be engineered and autonomously assembled with modular parts. With well-defined interfaces, custom instrumentation modules can easily be added to fit many mission objectives. Lunar Infrastructure Vision: At the LSIC spring meeting, ARMADAS will present a vision for a general-purpose lunar construction kit capable of meeting a wide variety of lunar surface infrastructure needs (Figure 1). Investing in an ecosystem of reconfigurable, discretely repairable parts and robots enables systems than can expand their capability, reconfigure to meet emergency or unforeseen needs, self-repair and reduce spare-part needs. With a small set of parts (module types), a wide variety of infrastructure needs can be met. Footing modules will allow infrastructure construction at locations with no surface preparation. Footer, primary structure, and rail modules can create reconfigurable rail systems. These rail systems can be used to reduce cost-of-transport between frequently accessed sites, provide dust mitigation, and convey power and communications. High-performance structure modules combined with power-routing and solar modules can create tall towers for power and communication. Concepts for habitats and garages encompass a structure to support regolith cover for a pre-integrated module to an entirely ARMADAS system-based structure. This system can be leveraged by many in-situ resource utilization (ISRU) technologies to simplify processes and augment capabilities.

C. E. Gregg↗

NASA NTRS1985

Monte Carlo simulation of a new gamma ray telescope

A new Monte Carlo code has been written to simulate the response of the new University of California double scatter gamma ray telescope. This package of modular software routines, written in VAX FORTRAN 77 simulates the detection of 0.1 to 35 MeV gamma rays. The new telescope is flown from high altitude balloons to measure medium energy gamma radiation from astronomical sources. This paper presents (1) the basic physics methods in the code, and (2) the predicted response functions of the telescope. Gamma ray processes include Compton scattering, pair production and photoelectric absorption in plastic scintillator, NaI(Tl) and aluminum. Electron transport processes include ionization energy loss, multiple scattering, production of bremsstrahlung photons and positron annihilation.

Simone, J.↗

NASA NTRS1993

A multimission three-axis stabilized spacecraft flight dynamics ground support system

The Multimission Three-Axis Stabilized Spacecraft (MTASS) Flight Dynamics Support System (FDSS) has been developed in an effort to minimize the costs of ground support systems. Unlike single-purpose ground support systems, which attempt to reduce costs by reusing software specifically developed for previous missions, the multimission support system is an intermediate step in the progression to a fully generalized mission support system in which numerous missions may be served by one general system. The benefits of multimission attitude ground support systems extend not only to the software design and coding process, but to the entire system environment, from specification through testing, simulation, operations, and maintenance. This paper reports the application of an MTASS FDSS to multiple scientific satellite missions. The satellites are the Upper Atmosphere Research Satellite (UARS), the Extreme Ultraviolet Explorer (EUVE), and the Solar Anomalous Magnetospheric Particle Explorer (SAMPEX). Both UARS and EUVE use the multimission modular spacecraft (MMS) concept. SAMPEX is part of the Small Explorer (SMEX) series and uses a much simpler set of attitude sensors. This paper centers on algorithm and design concepts for a multimission system and discusses flight experience from UARS.

Langston, J.↗

NASA NTRS2001

Geodynamo Modeling of Core-Mantle Interactions

Angular momentum exchange between the Earth's mantle and core influences the Earth's rotation on time scales of decades and longer, in particular in the length of day (LOD) which have been measured with progressively increasing accuracy for the last two centuries. There are four possible coupling mechanisms for transferring the axial angular momentum across the core-mantle boundary (CMB): viscous, magnetic, topography, and gravitational torques. Here we use our scalable, modularized, fully dynamic geodynamo model for the core to assess the importance of these torques. This numerical model, as an extension of the Kuang-Bloxham model that has successfully simulated the generation of the Earth's magnetic field, is used to obtain numerical results in various physical conditions in terms of specific parameterization consistent with the dynamical processes in the fluid outer core. The results show that depending on the electrical conductivity of the lower mantle and the amplitude of the boundary topography at CMB, both magnetic and topographic couplings can contribute significantly to the angular momentum exchange. This implies that the core-mantle interactions are far more complex than has been assumed and that there is unlikely a single dominant coupling mechanism for the observed decadal LOD variation.

Kuang, Wei-Jia↗

NASA NTRS2005

Simulation of Laser Cooling and Trapping in Engineering Applications

An advanced computer code is undergoing development for numerically simulating laser cooling and trapping of large numbers of atoms. The code is expected to be useful in practical engineering applications and to contribute to understanding of the roles that light, atomic collisions, background pressure, and numbers of particles play in experiments using laser-cooled and -trapped atoms. The code is based on semiclassical theories of the forces exerted on atoms by magnetic and optical fields. Whereas computer codes developed previously for the same purpose account for only a few physical mechanisms, this code incorporates many more physical mechanisms (including atomic collisions, sub-Doppler cooling mechanisms, Stark and Zeeman energy shifts, gravitation, and evanescent-wave phenomena) that affect laser-matter interactions and the cooling of atoms to submillikelvin temperatures. Moreover, whereas the prior codes can simulate the interactions of at most a few atoms with a resonant light field, the number of atoms that can be included in a simulation by the present code is limited only by computer memory. Hence, the present code represents more nearly completely the complex physics involved when using laser-cooled and -trapped atoms in engineering applications. Another advantage that the code incorporates is the possibility to analyze the interaction between cold atoms of different atomic number. Some properties that cold atoms of different atomic species have, like cross sections and the particular excited states they can occupy when interacting with each other and light fields, play important roles not yet completely understood in the new experiments that are under way in laboratories worldwide to form ultracold molecules. Other research efforts use cold atoms as holders of quantum information, and more recent developments in cavity quantum electrodynamics also use ultracold atoms to explore and expand new information-technology ideas. These experiments give a hint on the wide range of applications and technology developments that can be tackled using cold atoms and light fields. From more precise atomic clocks and gravity sensors to the development of quantum computers, there will be a need to completely understand the whole ensemble of physical mechanisms that play a role in the development of such technologies. The code also permits the study of the dynamic and steady-state operations of technologies that use cold atoms. The physical characteristics of lasers and fields can be time-controlled to give a realistic simulation of the processes involved such that the design process can determine the best control features to use. It is expected that with the features incorporated into the code it will become a tool for the useful application of ultracold atoms in engineering applications. Currently, the software is being used for the analysis and understanding of simple experiments using cold atoms, and for the design of a modular compact source of cold atoms to be used in future research and development projects. The results so far indicate that the code is a useful design instrument that shows good agreement with experimental measurements (see figure), and a Windows-based user-friendly interface is also under development.

Ramirez-Serrano, Jaime↗

NASA NTRS2021

Aircraft Engine Run-to-Failure Dataset Under Real Flight Conditions for Prognostics and Diagnostics

A key enabler of intelligent maintenance systems is the ability to predict the remaining useful lifetime (RUL) of its components, i.e., prognostics. The development of data-driven prognostics models requires datasets with run-to-failure trajectories. However, large representative run-to-failure datasets are often unavailable in real applications because failures are rare in many safety-critical systems. To foster the development of prognostics methods, we develop a new realistic dataset of run-to-failure trajectories for a fleet of aircraft engines under real flight conditions. The dataset was generated with the Commercial Modular Aero-Propulsion System Simulation (CMAPSS) model developed at NASA. The damage propagation modelling used in this dataset builds on the modelling strategy from previous work and incorporates two new levels of fidelity. First, it considers real flight conditions as recorded on board of a commercial jet. Second, it extends the degradation modelling by relating the degradation process to its operation history. This dataset also provides the health respectively fault class. Therefore, besides its applicability to prognostics problems, the dataset can be used for fault diagnostics.

CMAPPS↗

NASA NTRS2012

Status of the Correlation Process of the V-HAB Simulation with Ground Tests and ISS Telemetry Data

The Virtual Habitat (V-HAB) is a dynamic Life Support System (LSS) simulation, created to investigate future human spaceflight missions. V-HAB provides the capability to optimize LSS during early design phases. Furthermore, it allows simulation of worst case scenarios which cannot be tested in reality. In a nutshell, the tool allows the testing of LSS robustness by means of computer simulations. V-HAB is a modular simulation consisting of a: 1. Closed Environment Module 2. Crew Module 3. Biological Module 4. Physio-Chemical Module The focus of the paper will be the correlation and validation of V-HAB against ground test and flight data. The ECLSS technologies (CDRA, CCAA, OGA, etc.) are correlated one by one against available ground test data, which is briefly described in this paper. The technology models in V-HAB are merged to simulate the ISS ECLSS. This simulation is correlated against telemetry data from the ISS, including the water recovery system and the air revitalization system. Finally, an analysis of the results is included in this paper.

Ploetner, Peter↗

NASA NTRS1990

Modeling and optimization of a regenerative fuel cell system using the ASPEN process simulator

The Hydrogen-Oxygen Regenerative Fuel Cell System was identified as a key component for energy storage in support of future lunar missions. Since the H2-O2 regenerative electrochemical conversion technology has not yet been tested in space applications, it is necessary to implement predictive techniques to develop initial feasible system designs. The ASPEN simulation software furnishes a constructive medium for analyzing and optimizing such systems. A rudimentary regenerative fuel cell system design was examined using the ASPEN simulator and this modular approach allows for easy addition of supplementary ancillary components and easy integration with life support systems. The modules included in the preliminary analyses may serve as the fundamental structure for more complicated energy storage systems.

Maloney, Thomas M.↗

NASA NTRS1979

25 kW power module evolution study

This paper presents a study of evolutionary growth concepts for the 25 kW power module to augment STS mission support future capabilities. The study aimed to establish user payload requirements, define evolution methods for system initial operational capability, and formulate a development program and conceptual designs. The payload requirements analysis focused on material processing in space, public services, and solar terrestrial observations; evolutionary system concepts were evaluated to derive the power module and system support requirements, and four reference orbits were used to construct the nominal program scenario. The mission accomodations analysis evaluated the capability of the nominal program scenario and associated power module concepts to meet user needs. Finally, the recommended modular design consisting of electric power, attitude control, thermal control, and command and data handling is described, and it is concluded that the 25 kW power module is a logical first step to support the near term NASA sortie and free-flyer mission requirements.

Overall, J. W., Jr.↗