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Reliability and quality EEE parts issues

NASA policy and procedures are established which govern the selection, testing, and application of electrical, electronic, and electromechanical (EEE) parts. Recent advances in the state-of-the-art of electronic parts and associated technologies can significantly impact the electronic designs and reliability of NASA space transportation avionics. Significant issues that result from these advances are examined, including: recent advances in microelectronics technology (as applied to or considered for use in NASA projects); electron packaging technology advances (concurrent with, and as a result of, the development of the advanced microelectronic devices); availability of parts used in space avionics; and standardization and integration of parts activities between projects, centers, and contractors.

Barney, Dan

Simulating Avionics Upgrades to the Space Shuttles

Cockpit Avionics Prototyping Environment (CAPE) is a computer program that simulates the functions of proposed upgraded avionics for a space shuttle. In CAPE, pre-existing space-shuttle-simulation programs are merged with a commercial-off-the-shelf (COTS) display-development program, yielding a package of software that enables high-fi46 NASA Tech Briefs, September 2008 delity simulation while making it possible to rapidly change avionic displays and the underlying model algorithms. The pre-existing simulation programs are Shuttle Engineering Simulation, Shuttle Engineering Simulation II, Interactive Control and Docking Simulation, and Shuttle Mission Simulator playback. The COTS program Virtual Application Prototyping System (VAPS) not only enables the development of displays but also makes it possible to move data about, capture and process events, and connect to a simulation. VAPS also enables the user to write code in the C or C++ programming language and compile that code into the end-product simulation software. As many as ten different avionic-upgrade ideas can be incorporated in a single compilation and, thus, tested in a single simulation run. CAPE can be run in conjunction with any or all of four simulations, each representing a different phase of a space-shuttle flight.

Deger, Daniel

Mini AERCam: A Free-Flying Robot for Space Inspection

The NASA Johnson Space Center Engineering Directorate is developing the Autonomous Extravehicular Robotic Camera (AERCam), a free-flying camera system for remote viewing and inspection of human spacecraft. The AERCam project team is currently developing a miniaturized version of AERCam known as Mini AERCam, a spherical nanosatellite 7.5 inches in diameter. Mini AERCam development builds on the success of AERCam Sprint, a 1997 Space Shuttle flight experiment, by integrating new on-board sensing and processing capabilities while simultaneously reducing volume by 80%. Achieving these productivity-enhancing capabilities in a smaller package depends on aggressive component miniaturization. Technology innovations being incorporated include micro electromechanical system (MEMS) gyros, "camera-on-a-chip" CMOS imagers, rechargeable xenon gas propulsion, rechargeable lithium ion battery, custom avionics based on the PowerPC 740 microprocessor, GPS relative navigation, digital radio frequency communications and tracking, micropatch antennas, digital instrumentation, and dense mechanical packaging. The Mini AERCam free-flyer will initially be integrated into an approximate flight-like configuration for laboratory demonstration on an airbearing table. A pilot-in-the-loop and hardware-in-the-loop simulation to simulate on-orbit navigation and dynamics will complement the airbearing table demonstration. The Mini AERCam lab demonstration is intended to form the basis for future development of an AERCam flight system that provides on-orbit views of the Space Shuttle and International Space Station unobtainable from fixed cameras, cameras on robotic manipulators, or cameras carried by space-walking crewmembers.

Fredrickson, Steven

Lessons Learned from the Flight Unit Testing of the Near Earth Asteroid Scout Flight System

The Near Earth Asteroid Scout flight mission is set to launch on the maiden voyage of the Space Launch System as a secondary payload. The spacecraft will be jettisoned in cis-lunar space and embark on an ambitious 2.5 year mission to image an asteroid. The spacecraft is uniquely equipped with an 85m2 solar sail as the main propulsion system. The monolithic sail system is designed to package within a 6U volume for launch and then deploy during flight. The NEA Scout team has presented in the past to the International Symposium on Solar Sailing topics related to the engineering development unit and design efforts to achieve flight hardware build. This paper will focus on the lessons learned from building and testing the NEA Scout flight system. Focus will be on the mechanical, software, and electrical interfaces as well as preparation for subsystem environmental tests, including thermal vacuum. Due to the unique design of the spacecraft, the solar sail subsystem was required to be located in the center of the spacecraft. This requirement lead to design challenges such as designing and accommodating critical cable harnesses to run through the center of the sail subsystem, packaging and deployment design of the sail subsystem, and integrated testing efforts through an avionics test bed to verify and validate a complete system architecture.

Lockett, Tiffany Russell

Miniaturized Autonomous Extravehicular Robotic Camera (Mini AERCam)

The NASA Johnson Space Center (JSC) Engineering Directorate is developing the Autonomous Extravehicular Robotic Camera (AERCam), a low-volume, low-mass free-flying camera system . AERCam project team personnel recently initiated development of a miniaturized version of AERCam known as Mini AERCam. The Mini AERCam target design is a spherical "nanosatellite" free-flyer 7.5 inches in diameter and weighing 1 0 pounds. Mini AERCam is building on the success of the AERCam Sprint STS-87 flight experiment by adding new on-board sensing and processing capabilities while simultaneously reducing volume by 80%. Achieving enhanced capability in a smaller package depends on applying miniaturization technology across virtually all subsystems. Technology innovations being incorporated include micro electromechanical system (MEMS) gyros, "camera-on-a-chip" CMOS imagers, rechargeable xenon gas propulsion system , rechargeable lithium ion battery, custom avionics based on the PowerPC 740 microprocessor, GPS relative navigation, digital radio frequency communications and tracking, micropatch antennas, digital instrumentation, and dense mechanical packaging. The Mini AERCam free-flyer will initially be integrated into an approximate flight-like configuration for demonstration on an airbearing table. A pilot-in-the-loop and hardware-in-the-loop simulation to simulate on-orbit navigation and dynamics will complement the airbearing table demonstration. The Mini AERCam lab demonstration is intended to form the basis for future development of an AERCam flight system that provides beneficial on-orbit views unobtainable from fixed cameras, cameras on robotic manipulators, or cameras carried by EVA crewmembers.

Fredrickson, Steven E.

Integrated Avionics System (IAS)

As spacecraft designs converge toward miniaturization and with the volumetric and mass constraints placed on avionics, programs will continue to advance the 'state of the art' in spacecraft systems development with new challenges to reduce power, mass, and volume. Although new technologies have improved packaging densities, a total system packaging architecture is required that not only reduces spacecraft volume and mass budgets, but increase integration efficiencies, provide modularity and scalability to accommodate multiple missions. With these challenges in mind, a novel packaging approach incorporates solutions that provide broader environmental applications, more flexible system interconnectivity, scalability, and simplified assembly test and integration schemes. This paper will describe the fundamental elements of the Integrated Avionics System (IAS), Horizontally Mounted Cube (HMC) hardware design, system and environmental test results. Additional information is contained in the original extended abstract.

Hunter, D. J.

The NASA Radiation Hardness Assurance (RHA) Process Standard

This paper presents status on the upcoming NASA Agency-level RHA Process Standard. Based on recommendations provided by the NASA Engineering and Safety Center (NESC), the NASA Electronic Parts and Packaging (NEPP) Program has led development of an agency-level standard for space flight avionics and electronics RHA. The standard introduces a novel RHA taxonomy and prescribes the process required by NASA programs and projects to baseline their RHA programs consistent with the MEAL (Mission, Environment, Application, and Lifetime) criteria including the risk tolerance posture. The standard also provides requirements for the RHA schedule integration in the program or project lifecycle and requirements for data deliverables content. Additional non-prescriptive technical content is provided in the standard appendices to guide development of RHA programs for NASA missions.

Avionics

BRAINSTACK – A Platform for Artificial Intelligence & Machine Learning Collaborative Experiments on a Nano-Satellite

As space missions continue to become more ambitious, complex, and distant to Earth, the need for advanced on-board intelligent decision making to guide everything from mission operations to fault detection and recovery has become a major front of space research. While the prevalence of research on such Artificial Intelligence / Machine Learning (AI/ML) modules has exploded, the capacity to experimentally validate such modules in space in a rapid and inexpensive format has not. To this end, the Nano Orbital Workshop (NOW) group at NASA Ames Research Center has been at the forefront of performing initial flight evaluation tests of ‘commercially’ available AI/ML computational platforms via the TechEdSat (TES-n) flight series as part of what is programmatically referred to as the BRAINSTACK. BRAINSTACK will provide an orbital AI/ML evaluation laboratory where computational experiments are pre-loaded into memory prior to launch, and then executed as desired during the mission, with results reported back and program tweaks or new data sets uploaded as needed. Processors selected as part of the BRAINSTACK are of ideal size, packaging, and power consumption for easy integration into a cube satellite structure. These experiments have included the evaluation of small, high-performance GPUs and more recently, neuromorphic processors in LEO operations. Neuromorphic processors are of particular interest due to their superior computational power efficiency over GPUs. The first TES-n flight test of an Intel first-generation Loihi neuromorphic processor launched on January 13, 2022 and continues to operate in orbit despite almost no space environment modifications. The Intel Loihi Gen-1 is characterized by a 14nm 128-core Spiking Neural Network (SNN) able to support on-chip training. This experiment utilized a Loihi packaged in the ‘Kapoho Bay’ USB module, providing a relatively straight-forward interface to the bus avionics system. The Kapoho Bay was in turn managed by a host Intel Pentium single-board computer to handle scheduling of the AI/ML application payloads, and communications with the satellite vehicle manager. The recently released Intel Loihi Gen-2, able to support integer-valued spike payloads and produced using 7nm process, will form part of the basis of the evolving BRAINSTACK in the upcoming three TES-n/NOW flights. Additionally, it is planned to measure the radiation environment these processors experience to understand any degradation or computational artifacts caused by long term space radiation exposure on these novel architectures. This evolving flexible and collaborative environment involving various research teams across NASA and other organizations is intended to be a convenient orbital test platform from which many anticipated future space AI/ML applications may be initially tested.

Artificial Intelligence

BRAINSTACK – A Platform for Artificial Intelligence & Machine Learning Collaborative Experiments on a Nano-Satellite

As space missions continue to become more ambitious, complex, and distant to Earth, the need for advanced on-board intelligent decision making to guide everything from mission operations to fault detection and recovery has become a major front of space research. While the prevalence of research on such Artificial Intelligence / Machine Learning (AI/ML) modules has exploded, the capacity to experimentally validate such modules in space in a rapid and inexpensive format has not. To this end, the Nano Orbital Workshop (NOW) group at NASA Ames Research Center has been at the forefront of performing initial flight evaluation tests of ‘commercially’ available AI/ML computational platforms via the TechEdSat (TES-n) flight series as part of what is programmatically referred to as the BRAINSTACK. BRAINSTACK will provide an orbital AI/ML evaluation laboratory where computational experiments are pre-loaded into memory prior to launch, and then executed as desired during the mission, with results reported back and program tweaks or new data sets uploaded as needed. Processors selected as part of the BRAINSTACK are of ideal size, packaging, and power consumption for easy integration into a cube satellite structure. These experiments have included the evaluation of small, high-performance GPUs and more recently, neuromorphic processors in LEO operations. Neuromorphic processors are of particular interest due to their superior computational power efficiency over GPUs. The first TES-n flight test of an Intel first-generation Loihi neuromorphic processor launched on January 13, 2022 and continues to operate in orbit despite almost no space environment modifications. The Intel Loihi Gen-1 is characterized by a 14nm 128-core Spiking Neural Network (SNN) able to support on-chip training. This experiment utilized a Loihi packaged in the ‘Kapoho Bay’ USB module, providing a relatively straight-forward interface to the bus avionics system. The Kapoho Bay was in turn managed by a host Intel Pentium single-board computer to handle scheduling of the AI/ML application payloads, and communications with the satellite vehicle manager. The recently released Intel Loihi Gen-2, able to support integer-valued spike payloads and produced using 7nm process, will form part of the basis of the evolving BRAINSTACK in the upcoming three TES-n/NOW flights. Additionally, it is planned to measure the radiation environment these processors experience to understand any degradation or computational artifacts caused by long term space radiation exposure on these novel architectures. This evolving flexible and collaborative environment involving various research teams across NASA and other organizations is intended to be a convenient orbital test platform from which many anticipated future space AI/ML applications may be initially tested.

Artificial Intelligence

BRAINSTACK – A Platform for Artificial Intelligence & Machine Learning Collaborative Experiments on a Nano-Satellite

As the space economy continues to expand through increasingly easy access to advanced and inexpensive technology, space missions themselves have become more ambitious with exploration targets growing ever distant while simultaneously requiring larger guidance and communication budgets. These conflicting desires of distance and control drive the need for advanced on-board intelligent decision making to reduce communication and control limitations by automating as many mission functions as possible in-situ. While the amount of research on such Artificial Intelligence and Machine Learning (AI/ML) software modules has grown exponentially, the capacity to experimentally validate such software modules in space in a rapid and inexpensive format has not. To this end, the Nano Orbital Workshop (NOW) group at NASA Ames Research Center has been at the forefront of performing initial flight evaluation tests of ‘commercially’ available bleeding-edge computational platforms via what is programmatically referred to as the BrainStack on the TechEdSat (TES-n) flight series. This on-orbit computational platform provides an evaluation laboratory where advanced software experiments are pre-loaded into memory prior to launch, then executed as payloads during mission operations with results reported back and program tweaks or new training sets uploaded as needed. Processors selected as part of the BrainStack are of ideal size, packaging, and power consumption for easy integration into a cube satellite structure. These experiments have included the evaluation of small, high-performance GPUs and, more recently, neuromorphic processors, in LEO operations. Neuromorphic processors are of particular interest due to their superior power efficiency over GPUs in intelligent automation applications. The first TES-n flight test of an Intel first-generation Loihi neuromorphic processor launched on TES-13, January 13, 2022, and continues to operate in orbit despite no significant modifications to harden the processor against the space environment. The Intel Loihi Gen-1 on TES-13 is characterized by a 14nm 128-core Spiking Neural Network (SNN) able to support on-chip training. The processor is packaged in the Kapoho Bay USB module, providing a relatively straight-forward interface to the bus avionics system. The Kapoho Bay was in turn managed by an Intel Pentium single-board computer to handle scheduling of the software application payloads and communications with the satellite’s primary computer. The recently released Intel Loihi Gen-2, able to support integer-valued spike payloads and produced using 7nm process, will form part of the continually evolving BrainStack in the upcoming three TES-n/NOW flights. The Kapoho Point unit will incorporate eight Loihi-2 processors, enabling neural networks of up to one million neurons and one billion synapsis. Additionally, it is planned to measure the radiation environment these processors experience to understand any degradation or computational artifacts caused by long term space radiation exposure on these novel architectures. This evolving flexible and collaborative environment involving various research teams across NASA and other organizations is intended to be a convenient orbital test platform from which many anticipated future space automation applications may be initially tested.

Artificial Intelligence

30-kW SEP Spacecraft as Secondary Payloads for Low-Cost Deep Space Science Missions

The Solar Array System contracts awarded by NASA's Space Technology Mission Directorate are developing solar arrays in the 30 kW to 50 kW power range (beginning of life at 1 AU) that have significantly higher specific powers (W/kg) and much smaller stowed volumes than conventional rigid-panel arrays. The successful development of these solar array technologies has the potential to enable new types of solar electric propulsion (SEP) vehicles and missions. This paper describes a 30-kW electric propulsion vehicle built into an EELV Secondary Payload Adapter (ESPA) ring. The system uses an ESPA ring as the primary structure and packages two 15-kW Megaflex solar array wings, two 14-kW Hall thrusters, a hydrazine Reaction Control Subsystem (RCS), 220 kg of xenon, 26 kg of hydrazine, and an avionics module that contains all of the rest of the spacecraft bus functions and the instrument suite. Direct-drive is used to maximize the propulsion subsystem efficiency and minimize the resulting waste heat and required radiator area. This is critical for packaging a high-power spacecraft into a very small volume. The fully-margined system dry mass would be approximately 1120 kg. This is not a small dry mass for a Discovery-class spacecraft, for example, the Dawn spacecraft dry mass was only about 750 kg. But the Dawn electric propulsion subsystem could process a maximum input power of 2.5 kW, and this spacecraft would process 28 kW, an increase of more than a factor of ten. With direct-drive the specific impulse would be limited to about 2,000 s assuming a nominal solar array output voltage of 300 V. The resulting spacecraft would have a beginning of life acceleration that is more than an order of magnitude greater than the Dawn spacecraft. Since the spacecraft would be built into an ESPA ring it could be launched as a secondary payload to a geosynchronous transfer orbit significantly reducing the launch costs for a planetary spacecraft. The SEP system would perform the escape from Earth and then the heliocentric transfer to the science target.

Dawn spacecraft

Electrical Connectors

Betaflex connectors are sockets that connect multichip modules and high density ceramic packages to printed circuit boards. They incorporate shape memory alloy technology, developed under NASA contract. Aimed at computer, telecommunication, avionics and military markets, the connectors enable designers to gain up to 40 percent more board space and provide 100 signal lines to the inch. When the nickel titanium element in the connector is heated by a low voltage power supply, the connector's spring is opened allowing the circuit board to be inserted with zero force. This makes assembly easier and more reliable. Beta Phase was taken over by Mopex, BPS and currently manufactures these connectors.

Source record

Flight Guidance System Validation Using SPIN

To verify the requirements for the mode control logic of a Flight Guidance System (FGS) we applied SPIN, a widely used software package that supports the formal verification of distributed systems. These requirements, collectively called the FGS specification, were developed at Rockwell Avionics & Communications and expressed in terms of the Consortium Requirements Engineering (CoRE) method. The properties to be verified are the invariants formulated in the FGS specification, along with the standard properties of consistency and completeness. The project had two stages. First, the FGS specification and the properties to be verified were reformulated in PROMELA, the input language of SPIN. This involved a semantics issue, as some constructs of the FGS specification do not have well-defined semantics in CoRE. Then we attempted to verify the requirements' properties using the automatic model checking facilities of SPIN. Due to the large size of the state space of the FGS specification an exhaustive state space analysis with SPIN turned out to be impossible. So we used the supertrace model checking procedure of SPIN that provides for a partial analysis of the state space. During this process, we found some subtle errors in the FGS specification.

Naydich, Dimitri

Dynamic Control System Mode Performance of the Space Technology-7 Disturbance Reduction System

The Space Technology-7 (ST-7) Disturbance Reduction System (DRS) is an experiment package aboard the European Space Agency (ESA) LISA Pathfinder spacecraft, launched on December 3, 2015. DRS consists of three primary components: Colloidal MicroNewton Thrusters (CMNTs), an Integrated Avionics Unit (IAU), and flight-software implementing the Command and Data Handling (C&DH) and Dynamic Control System (DCS) algorithms. The CMNTs were designed to provide thrust from 5 to 30 micro Newton, with thrust controllability and resolution of 0.1 micro Newton and thrust noise of 0.1 micro Newton/(square root of (Hz)) in the measurement band from 1-30 mHz. The IAU hosts the C&DH and DCS flight software, as well as interfaces with both the CMNT electronics and the LISA Pathfinder spacecraft. When in control, the DCS uses star tracker attitude data and capacitive or optically-measured position and attitude information from LISA Pathfinder and the LISA Technology Package (LTP) to control the attitude and position of the spacecraft and the two test masses inside the LTP. After completion of the nominal ESA LISA Pathfinder mission, the DRS experiment was commissioned followed by its nominal mission. DRS operations extended over the next five months, interspersed with station keeping, anomaly resolution, and periods where control was handed back to LISA Pathfinder for them to conduct further experiments. The primary DRS mission ended on December 6, 2016, with the experiment meeting all of its Level 1 requirements. The DCS, developed at the NASA Goddard Space Flight Center, consists of five spacecraft control modes and six test mass control modes, combined into six 'DRS Mission Modes'. Attitude Control and Zero-G were primarily used to control the spacecraft during initial handover and during many of the CMNT characterization experiments. The other Mission Modes, Drag Free Low Force, 18-DOF Transitional, and 18-DOF, were used to provide drag-free control of the spacecraft about the test masses. This paper will discuss the performance of these DCS spacecraft and test mass control modes. Flight data will be shown from each mode throughout the mission, both from nominal operations and during various flight experiments. The DCS team also made some changes to controller, filter, and limit parameters during operations; the motivation and results of these changes will be shown and discussed.

O'Donnell, James R., Jr.

High-Payoff Space Transportation Design Approach with a Technology Integration Strategy

A general architectural design sequence is described to create a highly efficient, operable, and supportable design that achieves an affordable, repeatable, and sustainable transportation function. The paper covers the following aspects of this approach in more detail: (1) vehicle architectural concept considerations (including important strategies for greater reusability); (2) vehicle element propulsion system packaging considerations; (3) vehicle element functional definition; (4) external ground servicing and access considerations; and, (5) simplified guidance, navigation, flight control and avionics communications considerations. Additionally, a technology integration strategy is forwarded that includes: (a) ground and flight test prior to production commitments; (b) parallel stage propellant storage, such as concentric-nested tanks; (c) high thrust, LOX-rich, LOX-cooled first stage earth-to-orbit main engine; (d) non-toxic, day-of-launch-loaded propellants for upper stages and in-space propulsion; (e) electric propulsion and aero stage control.

McCleskey, C. M.

Orion Entry, Descent, and Landing Simulation

The Orion Entry, Descent, and Landing simulation was created over the past two years to serve as the primary Crew Exploration Vehicle guidance, navigation, and control (GN&C) design and analysis tool at the National Aeronautics and Space Administration (NASA). The Advanced NASA Technology Architecture for Exploration Studies (ANTARES) simulation is a six degree-of-freedom tool with a unique design architecture which has a high level of flexibility. This paper describes the decision history and motivations that guided the creation of this simulation tool. The capabilities of the models within ANTARES are presented in detail. Special attention is given to features of the highly flexible GN&C architecture and the details of the implemented GN&C algorithms. ANTARES provides a foundation simulation for the Orion Project that has already been successfully used for requirements analysis, system definition analysis, and preliminary GN&C design analysis. ANTARES will find useful application in engineering analysis, mission operations, crew training, avionics-in-the-loop testing, etc. This paper focuses on the entry simulation aspect of ANTARES, which is part of a bigger simulation package supporting the entire mission profile of the Orion vehicle. The unique aspects of entry GN&C design are covered, including how the simulation is being used for Monte Carlo dispersion analysis and for support of linear stability analysis. Sample simulation output from ANTARES is presented in an appendix.

Hoelscher, Brian R.

Power Extension Package (PEP) system definition extension, orbital service module systems analysis study. Volume 4: PEP functional specification

The functional, performance, design, and test requirements for the Orbiter power extension package and its associated ground support equipment are defined. Both government and nongovernment standards and specifications are cited for the following subsystems: electrical power, structural/mechanical, avionics, and thermal control. Quality control assurance provisions and preparation for delivery are also discussed.

Source record

Cryogenic Behavior of the High Temperature Crystal Oscillator PX-570

Microprocessors, data-acquisition systems, and electronic controllers usually require timing signals for proper and accurate operation. These signals are, in most cases, provided by circuits that utilize crystal oscillators due to availability, cost, ease of operation, and accuracy. Stability of these oscillators, i.e. crystal characteristics, is usually governed, amongst other things, by the ambient temperature. Operation of these devices under extreme temperatures requires, therefore, the implementation of some temperature-compensation mechanism either through the manufacturing process of the oscillator part or in the design of the circuit to maintain stability as well as accuracy. NASA future missions into deep space and planetary exploration necessitate operation of electronic instruments and systems in environments where extreme temperatures along with wide-range thermal swings are countered. Most of the commercial devices are very limited in terms of their specified operational temperature while very few custom-made and military-grade parts have the ability to operate in a slightly wider range of temperature. Thus, it is becomes mandatory to design and develop circuits that are capable of operation efficiently and reliably under the space harsh conditions. This report presents the results obtained on the evaluation of a new (COTS) commercial-off-the-shelf crystal oscillator under extreme temperatures. The device selected for evaluation comprised of a 10 MHz, PX-570-series crystal oscillator. This type of device was recently introduced by Vectron International and is designed as high temperature oscillator [1]. These parts are fabricated using proprietary manufacturing processes designed specifically for high temperature and harsh environment applications [1]. The oscillators have a wide continuous operating temperature range; making them ideal for use in military and aerospace industry, industrial process control, geophysical fields, avionics, and engine control. They exhibit low jitter and phase noise, consume little power, and are suited for high shock and vibration applications. The unique package design of these crystal oscillators offers a small ceramic package footprint, as well as providing both through-hole mounting and surface mount options.

Patterson, Richard