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Space station structures development

A study of three interrelated tasks focusing on deployable Space Station truss structures is discussed. Task 1, the development of an alternate deployment system for linear truss, resulted in the preliminary design of an in-space reloadable linear motor deployer. Task 2, advanced composites deployable truss development, resulted in the testing and evaluation of composite materials for struts used in a deployable linear truss. Task 3, assembly of structures in space/erectable structures, resulted in the preliminary design of Space Station pressurized module support structures. An independent, redundant support system was developed for the common United States modules.

Teller, V. B.

Some instrumentation requirement issues for the Space Station structural characterization experiment

The Space Station will provide unique opportunities to the research and technology community as a national in-space research facility. Opportunities will exist for technology experiments in a variety of disciplines, including dynamics and control of large space structures (LSS). The Space Station Structural Characterization Experiment (SSSCE) is an early space station technology experiment now under development. The objective of the experiment is to instrument and use the Space Station as a generic research test article, in support of research and technology activities in the areas of structural dynamics and control/structure interaction (CSI). Tests will be conducted, potentially, on each assembly flight configuration, as well as on the phase 1 configuration. Structural dynamic response data will be measured and transferred to the ground for analysis. These measurements will support the development and in-space verification of system identification and analytical modeling techniques for future LSS, including the evolutionary Space Station. The paper begins by restating the principal objective of SSSCE, along with the basic approach that will be used. The body of the paper deals with instrumentation requirement issues. The paper closes with several questions concerning modal-testing objectives and limitations, a brief review of a previous on-orbit experiment, the Solar Array Flight Experiment, and concluding remarks.

Pappa, Richard S.

In-space operations for lunar and Mars space transfer vehicles

The objective of this paper is to discuss the in-space operations required to process the lunar and Mars mission vehicles envisioned for the Space Exploration Initiative (SEI). Recent studies, which have examined the degree to which on-orbit operations change as a function of the Earth-to-orbit (ETO) launch vehicle size, identified a common set of on-orbit vehicle processing tasks, and generated functional requirements for in-space processing nodes are summarized in this paper. Timelines for on-orbit processing of two different lunar transfer vehicles (LTV's) were developed to compare a 'current practice,' labor-intensive EVA approach to ones utilizing telerobotics and advanced automation. LTV aerobrake concepts ranging from simple deployment to considerable assembly are compared. Similar timelines for the on-orbit processing of a nuclear Mars transfer vehicle (MTV) are also presented. Aerobrakes can be processed in a timely manner and should not be ruled out for SEI missions. The 'tall pole' time interval for on-orbit vehicle initial processing is the delivery of elements to orbit, not the processing tasks.

Raper, James L., Sr.

A&R challenges for in-space operations

Automation and robotics (A&R) challenges for in-space operations are examined, with emphasis on the interaction between developing requirements, developing solutions, design concepts, and the nature of the applicability of automation in robotic technologies. Attention is first given to the use of A&R in establishing outposts on the moon and Mars. Then emphasis is placed on the requirements for the assembly of transportation systems in low earth orbit. Concepts of the Space Station which show how the assembly, processing, and checkout of systems in LEO might be accommodated are examined.

Underwood, James

Investigating Laser Beam Welding as an In-Space Joining Technique via Thermal Vacuum and Microgravity and Vacuum Experiments

In-space joining technologies are crucial for stimulating an in-space economy and for enabling sustained space exploration by in-space manufacturing and repair of metallic structures. Compared to brazing or soldering, in-space welding (ISW) can provide highly hermetic, strong, and complex joints, potentially without introducing additional material. However, the influence of extreme temperatures, reduced pressure, and reduced gravity on ISW is not yet fully elucidated. Several efforts at NASA are investigating laser beam welding (LBW) as a joining and repair method in both thermal vacuum (TVAC) and combined vacuum & reduced gravity environments. NASA Marshall Space Flight Center (MSFC) shepherded several ISW projects in its past, including the 1973 electron beam welding on Skylab, the 1989 low-power LBW on parabolic flights, and the unflown 1990s-era In-Space Welding Experiment. Recent parabolic flights and 3 degree-of-freedom ground testing build upon this heritage. A collaboration with the Ohio State University using NASA Langley Research Center (LaRC) hardware retrofitted for LBW achieved the first high-powered laser welds under vacuum and low gravity and developed a workforce capable developing such experimental hardware. A ground testing campaign at the MSFC Flat Floor simulated fit-up and welding representative of ISW in 3 degrees of freedom to emulate microgravity effects on inertial systems. One ongoing effort is a NASA Early Career Initiative project – Lunar Assembly and Servicing by Autonomous Robotics (LASAR). Ruggedized LBW components were developed by an external partner for use in TVAC. A TVAC-rated robotic arm was procured by MSFC and used in the first known robotic laser weld where all components save the laser generator were under vacuum. NASA Johnson Space Center (JSC) is advancing supervised autonomy of ISW. NASA LaRC continues to adapt their unique snowflake joint geometry, suitable for connecting segments in trusses and other structures, to LBW. Upcoming TVAC campaigns will focus on testing extreme temperatures, proving out autonomous operations, and demonstrating weld repair. Weld inspection will occur via a non-contact nondestructive evaluation (NDE) technique – electromagnetic acoustic transduction (EMAT). Another ongoing effort based at MSFC is the DISCMAN -- DIsk-Shaped Configurable and Modular vAcuum uNit – which seeks to development a compact, modular payload that can provide a vacuum environment while in a reduced gravity condition. This payload could support multiple in-space manufacturing developmental efforts, with the first demonstration technology being LBW. Currently, the design is targeting operations in the pressurized volume of a space station, but the payload could readily be adapted to other flight platforms such as parabolic or even suborbital vehicles. LASAR elucidates the effects of temperature and vacuum on LBW while DISCMAN probes those of vacuum and gravity. Through these complementary efforts, NASA is addressing the primary challenges of ISW across the space environment while simultaneously developing and maturing technologies including robotic systems and inspection methodologies for future practical implementation on the Moon and beyond. This approach is timely, as upcoming missions requiring sustained human presence in space will depend on reliable ISW capabilities to create robust metallic joints currently unproven in the space environment and to perform repairs in situ .

hypogravity

Interaction dynamics of on-orbit construction

Deployment and assembly of large structures in orbit is a critical technology to the overall problem of orbital construction. The attendant large configuration changes of structures will cause significant changes in the dynamic characteristics of the entire system, and perturbation to the orbital dynamics of the spacecraft from which the structures are deployed and/or assembled. To better design structures for deployment and assembly, and to better design controlled deployment/assembly processes, accurate modeling techniques are absolutely essential. The problem of modeling the dynamics of deploying and retrieving beam-like structures from a rotating base was addressed. A methodology for discrete modeling, and a computational procedure were developed. These results give us the capability of understanding and predicting the effects on the overall satellite motion of deploying flexible appendages. This is an initial step towards a general capability of treating axially moving three-dimensional beams. The interaction dynamics of the orbiter, its flexible manipulator, and the structures to be assembled/deployed, as a prerequisite in order to simulate incremental in-space structural construction processes are investigated. Preliminary results so obtained indicate that, as the inertia properties of the flexible large space structure under construction change during the space assembly/construction process, the interaction dynamics undergo significant changes in their characteristics, thus revealing the need for a variety of control strategies throughout construction.

Park, K. C.

A path to in-space welding and to other in-space metal processing technologies using Space Shuttle small payloads

As we venture into space, it becomes necessary to assemble, expand, and repair space-based structures for our housing, research, and manufacturing. The zero gravity-vacuum of space challenges us to employ construction options which are commonplace on Earth. Rockwell International (RI) has begun to undertake the challenge of space-based construction via numerous options, of which one is welding. As of today, RI divisions have developed appropriate resources and technologies to bring space-based welding within our grasp. Further work, specifically in the area of developing space experiments to test RI technology, is required. RI Space Welding Project's achievements to date, from research and development (R&E) efforts in the areas of microgravity, vacuum, intra- / extra- vehicular activity and spinoff technologies, are reviewed. Special emphasis is given to results for G-169's (Get Away Special) microgravity flights aboard a NASA KC-135. Based on these achievements, a path to actual development of a space welding system is proposed with options to explore spinoff in-space metal processing technologies. This path is constructed by following a series of milestone experiments, of which several are to utilize NASA's Shuttle Small Payload Programs. Conceptual designs of the proposed shuttle payload experiments are discussed with application of lessons learned from G-169's design, development, integration, testing, safety approval process, and KC-135 flights.

Tamir, David

Next generation: In-space transportation system(s)

The development of the next generation In-Space Transportation System presents a unique challenge to the design of a propulsion system for the Space Exploration Initiative (SEI). Never before have the requirements for long-life, multiple mission use, space basing, high reliability, man-rating, and minimum maintenance come together with performance in one system that must protect the lives of space travelers, support the mission logistics needs, and do so at an acceptable cost. The challenge that is presented is to quantify the bounds of these requirements. The issue is one of degree. The length of acceptable life in space, the time it takes for reuse to pay off, and the degree to which space basing is practical (full, partial, or expended) are the issues that determine the reusable bounds of a design and include dependability, contingency capabilities, resilency, and minimum dependence on a maintenance node in preparation for and during a mission. Missions to planet earth, other non-NASA missions, and planetary missions will provide important but less demanding requirements for the transportation systems of the future. The mission proposed for the SEI require a family of transportation vehicles to meet the requirements for establishing a permanent human presence on the Moon and eventually on Mars. Specialized vehicles are needed to accomplish the different phases of each mission. These large scale missions require assembly in space and will provide the greatest usage of the planned integrated transportation system. The current approach to defining the In-Space Transportation System for the SEI Moon missions with later Mars mission applications is presented. Several system development options, propulsion concepts, current/proposed activities are reviewed, and key propulsion design criteria, issues, and technology challenges for the next generation In-Space Transportation System(s) are outlined.

Huffaker, Fredrick

Moisture loss from graphite structures for the Hubble Space Telescope

The construction and telescope assembly of the NASA's Hubble Space Telescope (HST) is described with particular reference to the features of its construction material. Due to the hygroscopic nature of the graphite-fiber reinforced epoxy, used for much of the structure of the HST, the telescope, when in orbit, suffers losses of water, absorbed during on-ground procedures, accompanied by shrinkage of the epoxy matrix, and needs periodic realignment. Using a combination of analytic, laboratory measured, and in-space measured data, an operational plan for adjusting the alignment of the HST is presented. The refocusing plan must take into account the preceding ground environment, as well as the prelaunch, lift-off, and predeployment environments of the HST-bearing Space Shuttle.

Facey, T. A.

In-space research, technology and engineering experiments and Space Station

The NASA Space Station will serve as a technology research laboratory, a payload-servicing facility, and a large structure fabrication and assembly facility. Space structures research will encompass advanced structural concepts and their dynamics, advanced control concepts, sensors, and actuators. Experiments dealing with fluid management will gather data on such fundamentals as multiphase flow phenomena. As requirements for power systems and thermal management grow, experiments quantifying the performance of energy systems and thermal management concepts will be undertaken, together with expanded efforts in the fields of information systems, automation, and robotics.

Tyson, Richard

Pathfinder: Surface exploration, in-space operations and space transfer

Viewgraphs on the Pathfinder program are presented. Information is given on technology needs, a planetary rover, program management, an autonomous lander, mission applications, orbital assembly, cryogenics, space nuclear reactors, space manufacturing, optical communications, spacecraft propulsion, aerobraking, and orbital transfer vehicles.

Mankins, John

Some test/analysis issues for the space station structural characterization experiment

The Space Station Structural Characterization Experiment (SSSCE) 1,2 is an early space flight experiment that uses the space station as a generic structure to study the dynamic characteristics of Large Space Structures (LSS). On-orbit modal testing will be conducted to determine natural frequencies, mode shapes and damping of dominant structural modes of the space structure assembly. This experiment will utimately support the development of system identification and analytical modeling techniques for Large Space Structures. In order to ensure the success of SSSCE (in-space validation of modeling techniques for LSS), adequate measurement and instrumentation requirements have to be established during the experiment-definition study. Among the issues affecting these requirements, spatial and modal coverages of the modal test data are of particular interest. Topics such as total number of sensors, type of measurements (translation and rotation), optimal sensor locations (measurement degrees-of-freedom), selection of target modes, effects of modal superposition and truncation, separation of global and local modes, etc., are all a fundamental importance and must be investigated.

Chou, Chaur-Ming

In-space construction and dynamics of large space structures

The types of equipment and structures that will be required to construct very large spacecraft in space are discussed. One of the basic issues that must be resolved is the appropriate mix of humans and machines in the construction process. While the use of robots offers the potential for reducing the number of extra-vehicular activity (EVA) hours required for particular construction operations, the availability of humans greatly increases the reliability of complex construction tasks. A hybrid system is described which makes the best use of man and machine to provide a highly reliable and versatile construction approach. Such a system will provide an efficient method for constructing large spacecraft until fully automated, robotic devices can be perfected. Details are given on an extensive ground test program which was designed to evaluate and demonstrate large spacecraft construction. A discussion is presented on the use of the Space Station Freedom, or an appropriate derivative, as a construction facility. Finally, a construction scenario and assembly timelines are presented for constructing a 20-meter-diameter high precision reflector.

Mikulas, Martin M., Jr.

An integrated in-space construction facility for the 21st century

This paper presents preliminary results of studies currently being conducted by NASA for constructing very large spacecraft. The paper discusses the various approaches for constructing spacecraft and their relative merits. As currently planned, Space Station Freedom has incorporated all of the basic design characteristics to permit its growth into an in-space construction facility for very large spacecraft. If disturbances from construction operations are intolerable to other experiments on Space Station Freedom, a co-orbiting construction facility could be built using truss hardware and systems previously for developed Space Station Freedom. The new PATHFINDER research initiative for on-orbit assembly and construction is also discussed. This research effort is aimed at developing construction methods for very large spacecraft and includes the development of a 100-meter-long space crane.

Mikulas, Martin M., Jr.

In-space technology experiments - Prerequisite for missions of the future

Experience with the Shuttle and free-flying satellites as technology test beds has shown the feasibility and desirability of using space assets as facilities for technology development. Thus, with the arrival of the Space Station Freedom era, technologists will be ready for an accessible engineering facility in space, particularly to support technology development for manned space exploration. As the 21st century is approached, virtually every flight to the Space Station Freedom will carry one or more research, technology and engineering experiments. The experiments planned will utilize both the pressurized volume and the external attachment facilities. A unique class of experiments will use the Space Station itself as an experimental test bed. Based upon recent examination of possible Space Station assembly sequences, technology payloads may utilize upwards of 20 percent of available resources.

Harris, Leonard A.

Vented Tank Resupply Experiment (VTRE) for In-space Technology Experiment Program (IN-STEP)

An overview of the Vented Tank Resupply Experiment (VTRE) program is presented in outline and graphical form. The goal of the program is to develop, design, build and provide flight and post flight support for a Shuttle Hitchhiker Experiment to investigate and demonstrate vented tank venting in space. Program schedules and experiment subsystem schematics are presented and specific technical objectives, power requirements, payload assemblies, Hitchhiker canister integration, and orbiter mission approach are addressed.

Source record

Advanced automation for in-space vehicle processing

The primary objective of this 3-year planned study is to assure that the fully evolved Space Station Freedom (SSF) can support automated processing of exploratory mission vehicles. Current study assessments show that required extravehicular activity (EVA) and to some extent intravehicular activity (IVA) manpower requirements for required processing tasks far exceeds the available manpower. Furthermore, many processing tasks are either hazardous operations or they exceed EVA capability. Thus, automation is essential for SSF transportation node functionality. Here, advanced automation represents the replacement of human performed tasks beyond the planned baseline automated tasks. Both physical tasks such as manipulation, assembly and actuation, and cognitive tasks such as visual inspection, monitoring and diagnosis, and task planning are considered. During this first year of activity both the Phobos/Gateway Mars Expedition and Lunar Evolution missions proposed by the Office of Exploration have been evaluated. A methodology for choosing optimal tasks to be automated has been developed. Processing tasks for both missions have been ranked on the basis of automation potential. The underlying concept in evaluating and describing processing tasks has been the use of a common set of 'Primitive' task descriptions. Primitive or standard tasks have been developed both for manual or crew processing and automated machine processing.

Sklar, Michael