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NASA NTRS2011

Constellation Program Lessons Learned: Detailed Lessons Learned - Volume 2

These lessons learned are part of a suite of hardware, software, test results, designs, knowledge base, and documentation that comprises the legacy of the Constellation Program. The context, summary information, and lessons learned are presented in a factual format, as known and described at the time. While our opinions might be discernable in the context, we have avoided all but factually sustainable statements. Statements should not be viewed as being either positive or negative; their value lies in what we did and what we learned that is worthy of passing on. The lessons include both "dos" and "don ts." In many cases, one person s "do" can be viewed as another person s "don t"; therefore, we have attempted to capture both perspectives when applicable and useful. While Volume I summarizes the views of those who managed the program, this Volume II encompasses the views at the working level, describing how the program challenges manifested in day-to-day activities. Here we see themes that were perhaps hinted at, but not completely addressed, in Volume I: unintended consequences of policies that worked well at higher levels but lacked proper implementation at the working level; long-term effects of the "generation gap" in human space flight development, the need to demonstrate early successes at the expense of thorough planning, and the consequences of problems and challenges not yet addressed because other problems and challenges were more immediate or manifest. Not all lessons learned have the benefit of being operationally vetted, since the program was cancelled shortly after Preliminary Design Review. We avoid making statements about operational consequences (with the exception of testing and test flights that did occur), but we do attempt to provide insight into how operational thinking influenced design and testing. The lessons have been formatted with a description, along with supporting information, a succinct statement of the lesson learned, and recommendations for future programs and projects that may be placed in similar circumstances.

Jennifer Rhatigan↗
NASA NTRS2007

Preliminary Performance Analyses of the Constellation Program ARES 1 Crew Launch Vehicle

By the time NASA's Exploration Systems Architecture Study (ESAS) report had been released to the public in December 2005, engineers at NASA's Marshall Space Flight Center had already initiated the first of a series of detailed design analysis cycles (DACs) for the Constellation Program Crew Launch Vehicle (CLV), which has been given the name Ares I. As a major component of the Constellation Architecture, the CLV's initial role will be to deliver crew and cargo aboard the newly conceived Crew Exploration Vehicle (CEV) to a staging orbit for eventual rendezvous with the International Space Station (ISS). However, the long-term goal and design focus of the CLV will be to provide launch services for a crewed CEV in support of lunar exploration missions. Key to the success of the CLV design effort and an integral part of each DAC is a detailed performance analysis tailored to assess nominal and dispersed performance of the vehicle, to determine performance sensitivities, and to generate design-driving dispersed trajectories. Results of these analyses provide valuable design information to the program for the current design as well as provide feedback to engineers on how to adjust the current design in order to maintain program goals. This paper presents a condensed subset of the CLV performance analyses performed during the CLV DAC-1 cycle. Deterministic studies include development of the CLV DAC-1 reference trajectories, identification of vehicle stage impact footprints, an assessment of launch window impacts to payload performance, and the computation of select CLV payload partials. Dispersion studies include definition of input uncertainties, Monte Carlo analysis of trajectory performance parameters based on input dispersions, assessment of CLV flight performance reserve (FPR), assessment of orbital insertion accuracy, and an assessment of bending load indicators due to dispersions in vehicle angle of attack and side slip angle. A short discussion of the various customers for the dispersion results, along with results and ramifications of each study, are also provided.

Phillips, Mark↗
NASA NTRS2010

Kennedy Space Center: Constellation Program Electrical Ground Support Equipment Research and Development

The Kennedy Space Center (KSC) is NASA's spaceport, launching rockets into space and leading important human spaceflight research. This spring semester, I worked at KSC on Constellation Program electrical ground support equipment through NASA's Undergraduate Student Research Program (USRP). This report includes a discussion of NASA, KSC, and my individual research project. An analysis of Penn State's preparation of me for an internship and my overall impressions of the Penn State and NASA internship experience conclude the report.

McCoy, Keegan↗
NASA NTRS2010

Constellation Program (CxP) Crew Exploration Vehicle (CEV) Parachute Assembly System (CPAS) Independent Design Reliability Assessment

This report documents the activities, findings, and NASA Engineering and Safety Center (NESC) recommendations of a multidiscipline team to independently assess the Constellation Program (CxP) Crew Exploration Vehicle (CEV) Parachute Assembly System (CPAS). This assessment occurred during a period of 15 noncontiguous months between December 2008 and April 2010, prior to the CPAS Project's Preliminary Design Review (PDR) in August 2010.

Kelly, Michael J.↗
NASA NTRS2010

The NASA Constellation Program Procedure System

NASA has used procedures to describe activities to be performed onboard vehicles by astronaut crew and on the ground by flight controllers since Apollo. Starting with later Space Shuttle missions and the International Space Station, NASA moved forward to electronic presentation of procedures. For the Constellation Program, another large step forward is being taken - to make procedures more interactive with the vehicle and to assist the crew in controlling the vehicle more efficiently and with less error. The overall name for the project is the Constellation Procedure Applications Software System (CxPASS). This paper describes some of the history behind this effort, the key concepts and operational paradigms that the work is based upon, and the actual products being developed to implement procedures for Constellation

Phillips, Robert G.↗
NASA NTRS2010

Constellation Program (CxP) Crew Exploration Vehicle (CEV) Parachute Assembly System (CPAS) Independent Design Reliability Assessment: Appendices - Volume 2

This document contains the Appendices to the report documenting the activities, findings, and NASA Engineering and Safety Center (NESC) recommendations of a multidiscipline team to independently assess the Constellation Program (CxP) Crew Exploration Vehicle (CEV) Parachute Assembly System (CPAS). The assessment occurred during a period of 15 noncontiguous months between December 2008 and April 2010, prior to the CPAS Project's Preliminary Design Review (PDR) in August 2010.

Kelly, Michael J.↗
NASA NTRS2009

Constellation Program Design Challenges as Opportunities for Educational Outreach and Workforce Development for Senior Design Classes

The Texas Space Grant Consortium (TSGC) and the Exploration Systems Mission Directorate (ESMD) both have programs that present design challenges for university senior design classes that offer great opportunities for educational outreach and workforce development. These design challenges have been identified by NASA engineers and researchers as real design problems faced by the Constellation Program in its exploration missions and architecture. Student teams formed in their senior design class select and then work on a design challenge for one or two semesters. The senior design class follows the requirements set by their university, but it must also comply with the Accreditation Board for Engineering and Technology (ABET) in order to meet the class academic requirements. Based on a one year fellowship at a TSGC university under the NASA Administrator's Fellowship Program (NAFP) and several years of experience, results and metrics are presented on the NASA Design Challenge Program.

Trevino, Robert C.↗
NASA NTRS2010

Constellation Program Design Challenges as Opportunities for Educational Outreach- Lessons Learned

The Texas Space Grant Consortium (TSGC) and the NASA Exploration Systems Mission Directorate (ESMD) Education Office both have programs that present design challenges for university senior design classes that offer great opportunities for educational outreach and workforce development. These design challenges have been identified by NASA engineers and scientists as actual design problems faced by the Constellation Program in its exploration missions and architecture. Student teams formed in their senior design class select and then work on a design challenge for one or two semesters. The senior design class follows the requirements set by their university, but it must also comply with the Accreditation Board for Engineering and Technology (ABET) in order to meet the class academic requirements. Based on a one year fellowship at a TSGC university under the NASA Administrator's Fellowship Program (NAFP) and several years of experience, lessons learned are presented on the NASA Design Challenge Program.

Trevino, Robert C.↗
NASA NTRS2007

Oxygen Concentration Flammability Thresholds of Selected Aerospace Materials Considered for the Constellation Program

Materials selection for spacecraft is based on an upward flammability test conducted in a quiescent environment in the highest expected oxygen concentration environment. The test conditions and its pass/fail test logic do not provide sufficient quantitative materials flammability information for an advanced space exploration program. A modified approach has been suggested determination of materials self-extinguishment limits. The flammability threshold information will allow NASA to identify materials with increased flammability risk from oxygen concentration and total pressure changes, minimize potential impacts, and allow for development of sound requirements for new spacecraft and extraterrestrial landers and habitats. This paper provides data on oxygen concentration self-extinguishment limits under quiescent conditions for selected materials considered for the Constellation Program.

Hirsch, David B.↗
NASA NTRS2008

Distributed Avionics and Software Verification for the Constellation Program

This viewgraph presentation reviews the planned verification of the avionics and software being developed for the Constellation program.The Constellation Distributed System Integration Laboratory (DSIL) will consist of multiple System Integration Labs (SILs), Simulators, Emulators, Testbeds, and Control Centers interacting with each other over a broadband network to provide virtual test systems for multiple test scenarios.

Hood, Laura E.↗
NASA NTRS2009

NASA Constellation Program (CxP) Key Driving Requirements and Element Descriptions for International Architecture Working Group (IAWG) Functional Teams Human Transportation Cargo Transportation

The NASA Constellation uncrewed cargo mission delivers cargo to any designated location on the lunar surface (or other staging point) in a single mission. This capability is used to deliver surface infrastructure needed for lunar outpost construction, to provide periodic logistics resupply to support a continuous human lunar presence, and potentially deliver other assets to various locations.In the nominal mission mode, the Altair lunar lander is launched on Ares V into Low Earth Orbit (LEO), following a short Low Earth Orbit (LEO) loiter period, the Earth Departure Stage (EDS) performs the Trans Lunar Injection (TLI) burn and is then jettisoned. The Altair performs translunar trajectory correction maneuvers as necessary and performs the Lunar Orbit Insertion (LOI) burn. Altair then descends to the surface to land near a designated target, presumably in proximity to an Outpost location or another site of interest for exploration.Alternatively, the EDS and Altair Descent Stage could deliver assets to various staging points within their propulsive capabilities.

Martinez, Roland M.↗
NASA NTRS2008

Ground Plane and Near-Surface Thermal Analysis for NASA's Constellation Program

Most spacecraft thermal analysis tools assume that the spacecraft is in orbit around a planet and are designed to calculate solar and planetary fluxes, as well as radiation to space. On NASA Constellation projects, thermal analysts are also building models of vehicles in their pre-launch condition on the surface of a planet. This process entails making some modifications in the building and execution of a thermal model such that the radiation from the planet, both reflected albedo and infrared, is calculated correctly. Also important in the calculation of pre-launch vehicle temperatures are the natural environments at the vehicle site, including air and ground temperatures, sky radiative background temperature, solar flux, and optical properties of the ground around the vehicle. A group of Constellation projects have collaborated on developing a cohesive, integrated set of natural environments that accurately capture worst-case thermal scenarios for the pre-launch and launch phases of these vehicles. The paper will discuss the standardization of methods for local planet modeling across Constellation projects, as well as the collection and consolidation of natural environments for launch sites. Methods for Earth as well as lunar sites will be discussed.

Gasbarre, Joseph F.↗
NASA NTRS2008

Does the Constellation Program Offer Opportunities to Achieve Space Science Goals in Space?

Future space science missions developed to achieve the most ambitious goals are likely to be complex, large, publicly and professionally very important, and at the limit of affordability. Consequently, it may be valuable if such missions can be upgraded, repaired, and/or deployed in space, either with robots or with astronauts. In response to a Request for Information from the US National Research Council panel on Science Opportunities Enabled by NASA's Constellation System, we developed a concept for astronaut-based in-space servicing at the Earth-Moon L1,2 locations that may be implemented by using elements of NASA's Constellation architecture. This libration point jobsite could be of great value for major heliospheric and astronomy missions operating at Earth-Sun Lagrange points. We explored five alternative servicing options that plausibly would be available within about a decade. We highlight one that we believe is both the least costly and most efficiently uses Constellation hardware that appears to be available by mid-next decade: the Ares I launch vehicle, Orion/Crew Exploration Vehicle, Centaur vehicle, and an airlock/servicing node developed for lunar surface operations. Our concept may be considered similar to the Apollo 8 mission: a valuable exercise before descent by astronauts to the lunar surface.

Thronson, Harley A.↗
NASA NTRS2006

The Challenges of Integrating NASA's Human, Budget, and Data Capital within the Constellation Program's Exploration Launch Projects Office

The U.S. Vision for Space Exploration directs NASA to retire the Space Shuttle in 2010 and replace it with safe, reliable, and cost-effective space transportation systems for crew and cargo travel to the Moon, Mars, and beyond. Such emerging space transportation initiatives face massive organizational challenges, including building and nurturing an experienced, dedicated team with the right skills for the required tasks; allocating and tracking the fiscal capital invested in achieving technical progress against an integrated master schedule; and turning generated data into usehl knowledge that equips the team to design and develop superior products for customers and stakeholders. This paper discusses how NASA's Exploration Launch Projects Office, which is responsible for delivering these new launch vehicles, integrates these resources to create an engineering business environment that promotes mission success.

Kidd, Luanne↗
NASA NTRS2007

Oxygen Concentration Flammability Threshold Tests for the Constellation Program

CEV atmosphere will likely change because craft will be used as LEO spacecraft, lunar spacecraft, orbital spacecraft. Possible O2 % increase and overall pressure decrease pressure vessel certs on spacecraft. Want 34% minimum threshold. Higher, better when atmosphere changes. WSTF suggests testing all materials/components to find flammability threshold, pressure and atmosphere.

Williams, James H.↗
NASA NTRS2007

Microbiological Monitoring for the Constellation Program: Current Requirements and Future Considerations

Microbiological requirements for spaceflight are based on assessments of infectious disease risk which could impact crew health or mission success. The determination of risk from infectious disease is composed of several factors including (1) crew susceptibility, (2) crew exposure to the infectious disease agent, (3) the concentration of the infectious agent, and (4) the characteristics of the infectious agent. As a result of the Health Stabilization Program, stringent monitoring, and cleaning protocols, in-flight environmental microbial monitoring is not necessary for short-duration spaceflights. However, risk factors change for long-duration missions, as exemplified by the presence of medically significant organisms in the environments of both the Mir and International Space Station (ISS). Based upon this historical evidence, requirements for short duration usage aboard the Orion Crew Exploration Vehicle and Lunar Lander Vehicle will not require in-flight monitoring; however, as mission duration increases with a Lunar Outpost, an ability to detect microbial hazard will be necessary. The nature of the detection requirements will depend on the maturity of technology in a rapidly evolving marketplace. Regardless, the hardware will still need to maximize information to discipline experts and the crew, while minimizing the size, mass, power consumption, and crew time usage. The refinement of these monitors will be a major goal in our efforts to travel successfully to Mars.

Ott, C. Mark↗