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NASA NTRS2016

Crew Exploration Vehicle (CEV) (Orion) Occupant Protection: Appendices - Part 1

Dr. Nancy J. Currie, of the NASA Engineering and Safety Center (NESC), Chief Engineer at Johnson Space Center (JSC), requested an assessment of the Crew Exploration Vehicle (CEV) occupant protection as a result of issues identified by the Constellation Program and Orion Project. The NESC, in collaboration with the Human Research Program (HRP), investigated new methods associated with occupant protection for the Crew Exploration Vehicle (CEV), known as Orion. The primary objective of this assessment was to investigate new methods associated with occupant protection for the CEV, known as Orion, that would ensure the design provided minimal risk to the crew during nominal and contingency landings in an acceptable set of environmental and spacecraft failure conditions. This documents contains the appendices to the NESC assessment report. NASA/TM-2013-217380, Application of the Brinkley Dynamic Response Criterion to Spacecraft Transient Dynamic Events supersedes this document.

Currie-Gregg, Nancy J.↗
NASA NTRS2009

Crew Exploration Vehicle (CEV) Avionics Integration Laboratory (CAIL) Independent Analysis

Two approaches were compared to the Crew Exploration Vehicle (CEV) Avionics Integration Laboratory (CAIL) approach: the Flat-Sat and Shuttle Avionics Integration Laboratory (SAIL). The Flat-Sat and CAIL/SAIL approaches are two different tools designed to mitigate different risks. Flat-Sat approach is designed to develop a mission concept into a flight avionics system and associated ground controller. The SAIL approach is designed to aid in the flight readiness verification of the flight avionics system. The approaches are complimentary in addressing both the system development risks and mission verification risks. The following NESC team findings were identified: The CAIL assumption is that the flight subsystems will be matured for the system level verification; The Flat-Sat and SAIL approaches are two different tools designed to mitigate different risks. The following NESC team recommendation was provided: Define, document, and manage a detailed interface between the design and development (EDL and other integration labs) to the verification laboratory (CAIL).

Davis, Mitchell L.↗
NASA NTRS2007

Crew Exploration Vehicle Environmental Control and Life Support Fire Protection Approach

As part of preparing for the Crew Exploration Vehicle (CEV), the National Aeronautics and Space Administration (NASA) worked on developing the requirements to manage the fire risk. The new CEV poses unique challenges to current fire protection systems. The size and configuration of the vehicle resembles the Apollo capsule instead of the current Space Shuttle or the International Space Station. The smaller free air volume and fully cold plated avionic bays of the CEV requires a different approach in fire protection than the ones currently utilized. The fire protection approach discussed in this paper incorporates historical lessons learned and fire detection and suppression system design philosophy spanning from Apollo to the International Space Station. Working with NASA fire and materials experts, this approach outlines the best requirements for both the closed out area of the vehicle, such as the avionics bay, and the crew cabin area to address the unique challenges due to the size and configuration of the CEV.

Lewis, John F.↗
NASA NTRS2007

Sonic Boom Assessment for the Crew Exploration Vehicle

The Constellation Environmental Impact Statement (Cx EIS) requires that an assessment be performed on the environmental impact of sonic booms during the reentry of the Crew Exploration Vehicle (CEV). This included an analysis of current planned vehicle trajectories for the Crew Module (CM) and the Service Module (SM) debris and the determination of the potential impact to the overflown environment.

Herron, Marissa↗
NASA NTRS2008

Adhesion of Silicone Elastomer Seals for NASA's Crew Exploration Vehicle

Silicone rubber seals are being considered for a number of interfaces on NASA's Crew Exploration Vehicle (CEV). Some of these joints include the docking system, hatches, and heat shield-to-back shell interface. A large diameter molded silicone seal is being developed for the Low Impact Docking System (LIDS) that forms an effective seal between the CEV and International Space Station (ISS) and other future Constellation Program spacecraft. Seals between the heat shield and back shell prevent high temperature reentry gases from leaking into the interface. Silicone rubber seals being considered for these locations have inherent adhesive tendencies that would result in excessive forces required to separate the joints if left unchecked. This paper summarizes adhesion assessments for both as-received and adhesion-mitigated seals for the docking system and the heat shield interface location. Three silicone elastomers were examined: Parker Hannifin S0899-50 and S0383-70 compounds, and Esterline ELA-SA-401 compound. For the docking system application various levels of exposure to atomic oxygen (AO) were evaluated. Moderate AO treatments did not lower the adhesive properties of S0899-50 sufficiently. However, AO pretreatments of approximately 10(exp 20) atoms/sq cm did lower the adhesion of S0383-70 and ELA-SA-401 to acceptable levels. For the heat shield-to-back shell interface application, a fabric covering was also considered. Molding Nomex fabric into the heat shield pressure seal appreciably reduced seal adhesion for the heat shield-to-back shell interface application.

deGroh, Henry C., III↗
NASA NTRS2007

Crew Exploration Vehicle Launch Abort System Flight Test Overview

The Constellation program is an organization within NASA whose mission is to create the new generation of spacecraft that will replace the Space Shuttle after its planned retirement in 2010. In the event of a catastrophic failure on the launch pad or launch vehicle during ascent, the successful use of the launch abort system will allow crew members to escape harm. The Flight Test Office is the organization within the Constellation project that will flight-test the launch abort system on the Orion crew exploration vehicle. The Flight Test Office has proposed six tests that will demonstrate the use of the launch abort system. These flight tests will be performed at the White Sands Missile Range in New Mexico and are similar in nature to the Apollo Little Joe II tests performed in the 1960s. An overview of the launch abort system flight tests for the Orion crew exploration vehicle is given. Details on the configuration of the first pad abort flight test are discussed. Sample flight trajectories for two of the six flight tests are shown.

Williams-Hayes, Peggy S.↗
NASA NTRS2007

Crew Exploration Vehicle Environmental Control and Life Support Emergency Gas Consumable Sizing

As part of preparing for the Crew Exploration Vehicle (CEV), the National Aeronautics and Space Administration (NASA) worked on developing the requirements that drive the emergency gas consumables. Emergency gas is required to support Extravehicular Activities (EVA), maintain the cabin pressure during a cabin leak for the crew to don their suits, and to recover the cabin following a toxic even or a fire.

Lewis, John F.↗
NASA NTRS2008

Aerothermodynamic Testing of Protuberances and Penetrations on the NASA Crew Exploration Vehicle Heat Shield in the NASA Langley 20-Inch Mach 6 Air Tunnel

An experimental wind tunnel program is being conducted in support of an Agency wide effort to develop a replacement for the Space Shuttle and to support the NASA s long-term objective of returning to the moon and then on to Mars. This paper documents experimental measurements made on several scaled ceramic heat transfer models of the proposed Crew Exploration Vehicle. Global heat transfer images and heat transfer distributions obtained using phosphor thermography were used to infer interference heating on the Crew Exploration Vehicle Cycle 1 heat shield from local protuberances and penetrations for both laminar and turbulent heating conditions. Test parametrics included free stream Reynolds numbers of 1.0x10(exp 6)/ft to 7.25x10(exp 6)/ft in Mach 6 air at a fixed angle-of-attack. Single arrays of discrete boundary layer trips were used to trip the boundary layer approaching the protuberances/penetrations to a turbulent state. Also, the effects of three compression pad diameters, two radial locations of compression pad/tension tie location, compression pad geometry, and rotational position of compression pad/tension tie were examined. The experimental data highlighted in this paper are to be used to validate CFD tools that will be used to generate the flight aerothermodynamic database. Heat transfer measurements will also assist in the determination of the most appropriate engineering methods that will be used to assess local flight environments associated with protuberances/penetrations of the CEV thermal protection system.

Liechty, Derek S.↗
NASA NTRS2007

Crew Exploration Vehicle Environmental Control and Life Support Design Reference Missions

In preparation for the contract award of the Crew Exploration Vehicle (CEV), the National Aeronautics and Space Administration (NASA) produced two design reference missions for the vehicle. The design references used teams of engineers across the agency to come up with two configurations. This process helped NASA understand the conflicts and limitations in the CEV design, and investigate options to solve them.

Lewis, John F.↗
NASA NTRS2008

Orion Crew Exploration Vehicle Launch Abort System Guidance and Control Analysis Overview

Aborts during the critical ascent flight phase require the design and operation of Orion Crew Exploration Vehicle (CEV) systems to escape from the Crew Launch Vehicle (CLV) and return the crew safely to the Earth. To accomplish this requirement of continuous abort coverage, CEV ascent abort modes are being designed and analyzed to accommodate the velocity, altitude, atmospheric, and vehicle configuration changes that occur during ascent. Aborts from the launch pad to early in the flight of the CLV second stage are performed using the Launch Abort System (LAS). During this type of abort, the LAS Abort Motor is used to pull the Crew Module (CM) safely away from the CLV and Service Module (SM). LAS abort guidance and control studies and design trades are being conducted so that more informed decisions can be made regarding the vehicle abort requirements, design, and operation. This paper presents an overview of the Orion CEV, an overview of the LAS ascent abort mode, and a summary of key LAS abort analysis methods and results.

Davidson, John B.↗
NASA NTRS2010

Constellation Probabilistic Risk Assessment (PRA): Design Consideration for the Crew Exploration Vehicle

Managed by NASA's Office of Safety and Mission Assurance, a pilot probabilistic risk analysis (PRA) of the NASA Crew Exploration Vehicle (CEV) was performed in early 2006. The PRA methods used follow the general guidance provided in the NASA PRA Procedures Guide for NASA Managers and Practitioners'. Phased-mission based event trees and fault trees are used to model a lunar sortie mission of the CEV - involving the following phases: launch of a cargo vessel and a crew vessel; rendezvous of these two vessels in low Earth orbit; transit to th$: moon; lunar surface activities; ascension &om the lunar surface; and return to Earth. The analysis is based upon assumptions, preliminary system diagrams, and failure data that may involve large uncertainties or may lack formal validation. Furthermore, some of the data used were based upon expert judgment or extrapolated from similar components~systemsT. his paper includes a discussion of the system-level models and provides an overview of the analysis results used to identify insights into CEV risk drivers, and trade and sensitivity studies. Lastly, the PRA model was used to determine changes in risk as the system configurations or key parameters are modified.

Prassinos, Peter G.↗
NASA NTRS2009

Occupant Protection during Orion Crew Exploration Vehicle Landings

The constellation program is evaluating current vehicle design capabilities for nominal water landings and contingency land landings of the Orion Crew Exploration vehicle. The Orion Landing Strategy tiger team was formed to lead the technical effort for which associated activities include the current vehicle design, susceptibility to roll control and tip over, reviewing methods for assessing occupant injury during ascent / aborts /landings, developing an alternate seat/attenuation design solution which improves occupant protection and operability, and testing the seat/attenuation system designs to ensure valid results. The EVA physiology, systems and Performance (EPSP) project is leading the effort under the authority of the Tiger Team Steering committee to develop, verify, validate and accredit biodynamics models using a variety of crash and injury databases including NASCAR, Indy Car and military aircraft. The validated biodynamics models will be used by the Constellation program to evaluate a variety of vehicle, seat and restraint designs in the context of multiple nominal and off-nominal landing scenarios. The models will be used in conjunction with Acceptable Injury Risk definitions to provide new occupant protection requirements for the Constellation Program.

Gernhardt, Michael L.↗
NASA NTRS2008

Development and Testing of a Sorbent-Based Atmosphere Revitalization System for the Crew Exploration Vehicle 2007/2008

The design of a Vacuum-Swing Adsorption (VSA) system to remove metabolic water and metabolic carbon dioxide from the Orion Crew Exploration Vehicle (CEV) atmosphere is presented. The approach for Orion is a VSA system that removes not only 100 percent of the metabolic CO2 from the atmosphere, but also 100% of the metabolic water as well, a technology approach that has not been used in previous spacecraft life support systems. The design and development of the Sorbent Based Atmosphere Regeneration (SBAR) system, including test articles, a facility test stand, and full-scale testing in late 2007 and early 2008 is discussed.

Knox, James C.↗
NASA NTRS2007

Testing of the Crew Exploration Vehicle in NASA Langley's Unitary Plan Wind Tunnel

As part of a strategic, multi-facility test program, subscale testing of NASA s Crew Exploration Vehicle was conducted in both legs of NASA Langley s Unitary Plan Wind Tunnel. The objectives of these tests were to generate aerodynamic and surface pressure data over a range of supersonic Mach numbers and reentry angles of attack for experimental and computational validation and aerodynamic database development. To provide initial information on boundary layer transition at supersonic test conditions, transition studies were conducted using temperature sensitive paint and infrared thermography optical techniques. To support implementation of these optical diagnostics in the Unitary Wind Tunnel, the experiment was first modeled using the Virtual Diagnostics Interface software. For reentry orientations of 140 to 170 degrees (heat shield forward), windward surface flow was entirely laminar for freestream unit Reynolds numbers equal to or less than 3 million per foot. Optical techniques showed qualitative evidence of forced transition on the windward heat shield with application of both distributed grit and discreet trip dots. Longitudinal static force and moment data showed the largest differences with Mach number and angle of attack variations. Differences associated with Reynolds number variation and/or laminar versus turbulent flow on the heat shield were very small. Static surface pressure data supported the aforementioned trends with Mach number, Reynolds number, and angle of attack.

Murphy, Kelly J.↗
NASA NTRS2006

Development and Testing of a Sorbent-Based Atmosphere Revitalization System for the Crew Exploration Vehicle

The design of a vacuum-swing adsorption process to remove metabolic water, metabolic carbon dioxide, and metabolic and equipment generated trace contaminant gases from the Crew Exploration Vehicle (CEV) atmosphere is presented. For the CEV, the approach is taken that all metabolic water must be removed by the Sorbent-Based Atmosphere Revitalization System (SBAR), a technology approach that has not been used in previous spacecraft life support systems. Design and development of a prototype SBAR, a facility test stand, and subsequent testing of the SBAR is discussed.

Knox, James C.↗
NASA NTRS2007

Deployable Landing Leg Concept for Crew Exploration Vehicle

The NASA Exploration program is investigating the merits of land landing concepts for the Crew Exploration Vehicle (CEV). Four options are under investigation: retro-rockets which fire and slow the vehicle before contact with the landing surface, deployable crushable material which deploys just before landing and crushes during land contact, airbags which deploy just before landing and deflate during land contact, and deployable legs which deploy before landing and contain material that absorbs energy during land contact. The purpose of the present work is to determine the effectiveness of the deployable leg concept. To accomplish this goal, structural models of the deployable leg concept are integrated with the Crew Model (CM) and computational simulations are performed to determine vehicle and component loadings and acceleration levels. Details of the modeling approach, deployable leg design, and resulting accelerations are provided.

Lawrence, Charles↗
NASA NTRS2010

Lidar Wind Profiler Comparison to Weather Balloon for Support of Orion Crew Exploration Vehicle Landings

A comparison study by the National Aeronautics and Space Administration Dryden Flight Research Center, Edwards, CA and the Naval Post Graduate School Center for Interdisciplinary Remotely-Piloted Aircraft Studies, Marina, CA was conducted to show the advantages of an airborne wind profiling lidar system in reducing drift uncertainty along a reentry vehicle descent trajectory. This effort was in support of the once planned Orion Crew Exploration Vehicle ground landing. A Twin Otter Doppler Wind Lidar was flown on multiple flights along the approximate ground track of an ascending weather balloons launched from the Marina Municipal Airport. The airborne lidar used was a 5-milli-Joules, 2-micron infrared laser with a 10-centimeter telescope and a two-axis scanner. Each lidar wind profile contains data for an altitude range between the surface and flight altitude of 2,700 meters, processed on board every 20 seconds. In comparison, a typical weather balloon would traverse that same altitude range with a similar data set available in approximately 15-20 minutes. These tests were conducted on November 15 & 16, 2007. Results comparing the balloon and a 10 minute multiple lidar profile averages show a best case absolute difference of 0.18 m/s (0.35 knots) in speed and 1 degree in direction during light and variable (less than 5 knots, without constant direction) wind conditions. These limited test results indicated a standard deviation wind velocity and direction differences of 0.71 m/s (1.3 knots) and 7.17 degrees for 1800Z, and 0.70 m/s (1.3 knots) and 6.79 degrees, outside of cloud layer.

Houtas, Franzeska↗
NASA NTRS2010

Lidar Wind Profiler Comparison to Weather Balloon for Support of Orion Crew Exploration Vehicle Landings

A comparison study by the National Aeronautics and Space Administration Dryden Flight Research Center (Edwards, California) and the Naval Post Graduate School Center for Interdisciplinary Remotely-Piloted Aircraft Studies (Marina, California) was conducted to show the advantages of an airborne wind profiling light detection and ranging (lidar) system in reducing drift uncertainty along a reentry vehicle descent trajectory. This effort was in support of the once planned Orion Crew Exploration Vehicle ground landing. A Twin Otter Doppler Wind Lidar was flown on multiple flights along the approximate ground track of each ascending weather balloon launched from the Marina Municipal Airport (Marina, California). The airborne lidar used was a 5-mJ, 2-micron infrared laser with a 10-cm telescope and a two-axis scanner. Each lidar wind profile contains data for an altitude range between the surface and flight altitude of 2.7 km, processed on board every 20 s. In comparison, a typical weather balloon would traverse that same altitude range with a similar data set available in approximately 15 to 20 min. These tests were conducted on November 15 and 16, 2007. Results show a best-case absolute difference of 0.18 m/s (0.35 knots) in speed and 1 degree in direct

Houtas, Franzeska F.↗