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NASA NTRS1986

An expert system prototype for aiding in the development of software functional requirements for NASA Goddard's command management system: A case study and lessons learned

At NASA Goddard, the role of the command management system (CMS) is to transform general requests for spacecraft opeerations into detailed operational plans to be uplinked to the spacecraft. The CMS is part of the NASA Data System which entails the downlink of science and engineering data from NASA near-earth satellites to the user, and the uplink of command and control data to the spacecraft. Presently, it takes one to three years, with meetings once or twice a week, to determine functional requirements for CMS software design. As an alternative approach to the present technique of developing CMS software functional requirements, an expert system prototype was developed to aid in this function. Specifically, the knowledge base was formulated through interactions with domain experts, and was then linked to an existing expert system application generator called 'Knowledge Engineering System (Version 1.3).' Knowledge base development focused on four major steps: (1) develop the problem-oriented attribute hierachy; (2) determine the knowledge management approach; (3) encode the knowledge base; and (4) validate, test, certify, and evaluate the knowledge base and the expert system prototype as a whole. Backcasting was accomplished for validating and testing the expert system prototype. Knowledge refinement, evaluation, and implementation procedures of the expert system prototype were then transacted.

Liebowitz, Jay↗

NASA NTRS1991

Structured prototyping as risk management

A methodology is presented for integrating the systems-engineering management recommendation of prototyping into the traditional project-management process for developing large-scale systems. The suggested methodology begins with the identification of life-cycle risk areas, outlines the structure and conduct of the prototyping process, and defines the composition of the prototyping team. The methodology includes a step-by-step procedure for creating, executing, and documenting a prototyping test plan to evaluate design alternatives. It is argued that managers who adopt this methodology and apply it rigorously will increase the likelihood that the systems they build will be operationally effective and will be accepted by the intended users.

Hornstein, Rhoda SH.↗

NASA NTRS1992

A process for prototyping onboard payload displays for Space Station Freedom

Significant advances have been made in the area of Human-Computer Interface design. However, there is no well-defined process for going from user interface requirements to user interface design. Developing and designing a clear and consistent user interface for medium to large scale systems is a very challenging and complex task. The task becomes increasingly difficult when there is very little guidance and procedures on how the development process should flow from one stage to the next. Without a specific sequence of development steps each design becomes difficult to repeat, to evaluate, to improve, and to articulate to others. This research contributes a process which identifies the phases of development and products produced as a result of each phase for a rapid prototyping process to be used to develop requirements for the onboard payload displays for Space Station Freedom. The functional components of a dynamic prototyping environment in which this process can be carried out is also discussed. Some of the central questions which are answered here include: How does one go from specifications to an actual prototype? How is a prototype evaluated? How is usability defined and thus measured? How do we use the information from evaluation in redesign of an interface? and Are there techniques which allow for convergence on a design?

Moore, Loretta A.↗

NASA NTRS1989

The Galileo PPS expert monitoring and diagnostic prototype

The Galileo PPS Expert Monitoring Module (EMM) is a prototype system implemented on the SUN workstation that will demonstrate a knowledge-based approach to monitoring and diagnosis for the Galileo spacecraft Power/Pyro subsystems. The prototype will simulate an analysis module functioning within the SFOC Engineering Analysis Subsystem Environment (EASE). This document describes the implementation of a prototype EMM for the Galileo spacecraft Power Pyro Subsystem. Section 2 of this document provides an overview of the issues in monitoring and diagnosis and comparison between traditional and knowledge-based solutions to this problem. Section 3 describes various tradeoffs which must be considered when designing a knowledge-based approach to monitoring and diagnosis, and section 4 discusses how these issues were resolved in constructing the prototype. Section 5 presents conclusions and recommendations for constructing a full-scale demonstration of the EMM. A Glossary provides definitions of terms used in this text.

Bahrami, Khosrow↗

NASA NTRS1994

Integration/evaluation of a HCI prototyping environment

Components of a human computer interface (HCI) prototyping environment have been integrated and evaluated. This environment will be valuable in developing and refining HCI standards and evaluating program/project interface development, especially the International Space Station Alpha's on-board displays for payload operations. This environment, which allows for rapid prototyping and evaluation of graphical interfaces, includes four components: (1) a HCI format development tool, (2) a test and evaluation simulator development tool, (3) a dynamic, interactive interface between the HCI prototype and simulator, and (4) an embedded evaluation capability to evaluate the adequacy of a HCI based on a user's performance. The objective of the research was to determine whether or not the functional components could be integrated and could provide the needed functionality for a rapid prototyping environment.

Moore, Loretta A.↗

NASA NTRS1991

PERTS: A Prototyping Environment for Real-Time Systems

We discuss an ongoing project to build a Prototyping Environment for Real-Time Systems, called PERTS. PERTS is a unique prototyping environment in that it has (1) tools and performance models for the analysis and evaluation of real-time prototype systems, (2) building blocks for flexible real-time programs and the support system software, (3) basic building blocks of distributed and intelligent real time applications, and (4) an execution environment. PERTS will make the recent and future theoretical advances in real-time system design and engineering readily usable to practitioners. In particular, it will provide an environment for the use and evaluation of new design approaches, for experimentation with alternative system building blocks and for the analysis and performance profiling of prototype real-time systems.

Liu, Jane W. S.↗

NASA NTRS2003

Development of a Prototype Nickel Optic for the Constellation-X Hard-X-Ray Telescope

The Constellation-X mission, planned for launch in 2011, will feature an array of hard-x ray telescopes with a total collecting area goal of 1500 square centimeters at 40 keV. Various technologies are currently being investigated for the optics of these telescopes including multilayer-coated Eletroformed-Nickel-Replicated (ENR) shells. The attraction of the ENR process is that the resulting full-shell optics are inherently stable and offer the promise of good angular resolution and enhanced instrument sensitivity. The challenge for this process is to meet a relatively tight weight budget with a relatively dense material (rho nickel = 9 grams per cubic centimeters.) To demonstrate the viability of the ENR process we are fabricating a prototype HXT mirror module to be tested against a competing segmented-glass-shell optic. The ENR prototype will consist of 5 shells of diameters from 150 mm to 280 mm and of 426 mm total length. To meet the stringent weight budget for Con-X, the shells will be only 150 micron thick. The innermost of these will be coated with Iridium, while the remainder will be coated with graded-density multilayers. Mandrels for these shells are currently under fabrication (Jan 03), with the first shells scheduled for production in February 03. A tentative date of late Summer has been set for prototype testing. Issues currently being addressed are the control of stresses in the multiplayer coating and ways of mitigating their effects on the figure of the necessarily thin shells. Also, the fabrication, handling and mounting of these shells without inducing permanent figure distortions. A full status report on the prototype optic will be presented along with test results as available.

Basso, S.↗

NASA NTRS2003

Prompt and Precise Prototyping

For Sanders Design International, Inc., of Wilton, New Hampshire, every passing second between the concept and realization of a product is essential to succeed in the rapid prototyping industry where amongst heavy competition, faster time-to-market means more business. To separate itself from its rivals, Sanders Design aligned with NASA's Marshall Space Flight Center to develop what it considers to be the most accurate rapid prototyping machine for fabrication of extremely precise tooling prototypes. The company's Rapid ToolMaker System has revolutionized production of high quality, small-to-medium sized prototype patterns and tooling molds with an exactness that surpasses that of computer numerically-controlled (CNC) machining devices. Created with funding and support from Marshall under a Small Business Innovation Research (SBIR) contract, the Rapid ToolMaker is a dual-use technology with applications in both commercial and military aerospace fields. The advanced technology provides cost savings in the design and manufacturing of automotive, electronic, and medical parts, as well as in other areas of consumer interest, such as jewelry and toys. For aerospace applications, the Rapid ToolMaker enables fabrication of high-quality turbine and compressor blades for jet engines on unmanned air vehicles, aircraft, and missiles.

Source record↗

NASA NTRS2003

Demonstrating a Realistic IP Mission Prototype

Flight software and hardware and realistic space communications environments were elements of recent demonstrations of the Internet Protocol (IP) mission concept in the lab. The Operating Missions as Nodes on the Internet (OMNI) Project and the Flight Software Branch at NASA/GSFC collaborated to build the prototype of a representative space mission that employed unmodified off-the-shelf Internet protocols and technologies for end-to-end communications between the spacecraft/instruments and the ground system/users. The realistic elements used in the prototype included an RF communications link simulator and components of the TRIANA mission flight software and ground support system. A web-enabled camera connected to the spacecraft computer via an Ethernet LAN represented an on-board instrument creating image data. In addition to the protocols at the link layer (HDLC), transport layer (UDP, TCP), and network (IP) layer, a reliable file delivery protocol (MDP) at the application layer enabled reliable data delivery both to and from the spacecraft. The standard Network Time Protocol (NTP) performed on-board clock synchronization with a ground time standard. The demonstrations of the prototype mission illustrated some of the advantages of using Internet standards and technologies for space missions, but also helped identify issues that must be addressed. These issues include applicability to embedded real-time systems on flight-qualified hardware, range of applicability of TCP, and liability for and maintenance of commercial off-the-shelf (COTS) products. The NASA Earth Science Technology Office (ESTO) funded the collaboration to build and demonstrate the prototype IP mission.

Rash, James↗

NASA NTRS2004

Prototype Morphing Fan Nozzle Demonstrated

Ongoing research in NASA Glenn Research Center's Structural Mechanics and Dynamics Branch to develop smart materials technologies for aeropropulsion structural components has resulted in the design of the prototype morphing fan nozzle shown in the photograph. This prototype exploits the potential of smart materials to significantly improve the performance of existing aircraft engines by introducing new inherent capabilities for shape control, vibration damping, noise reduction, health monitoring, and flow manipulation. The novel design employs two different smart materials, a shape-memory alloy and magnetorheological fluids, to reduce the nozzle area by up to 30 percent. The prototype of the variable-area fan nozzle implements an overlapping spring leaf assembly to simplify the initial design and to provide ease of structural control. A single bundle of shape memory alloy wire actuators is used to reduce the nozzle geometry. The nozzle is subsequently held in the reduced-area configuration by using magnetorheological fluid brakes. This prototype uses the inherent advantages of shape memory alloys in providing large induced strains and of magnetorheological fluids in generating large resistive forces. In addition, the spring leaf design also functions as a return spring, once the magnetorheological fluid brakes are released, to help force the shape memory alloy wires to return to their original position. A computerized real-time control system uses the derivative-gain and proportional-gain algorithms to operate the system. This design represents a novel approach to the active control of high-bypass-ratio turbofan engines. Researchers have estimated that such engines will reduce thrust specific fuel consumption by 9 percent over that of fixed-geometry fan nozzles. This research was conducted under a cooperative agreement (NCC3-839) at the University of Akron.

Lee, Ho-Jun↗

NASA NTRS2007

A One-Piece Lunar Regolith Bag Garage Prototype

Shelter structures on the moon, even in early phases of exploration, should incorporate lunar materials as much as possible. This Technical Memorandum details the design and construction of a prototype for a one-piece regolith bag unpressurized garage concept and a materials testing program to investigate six candidate fabrics to learn how they might perform in the lunar environment. The conceptualization was that a lightweight fabric form be launched from Earth and landed on the lunar surface to be robotically filled with raw lunar regolith. Regolith bag fabric candidates included: Vectran(TM), Nextel(TM), Gore PTFE Fabric(TM), Zylon(TM), Twaron(TM), and Nomex(TM). Tensile (including post radiation exposure), fold, abrasion, and hypervelocity impact testing were performed under ambient conditions, and also performed under cold and elevated temperatures. In some cases, Johnson Space Center lunar simulant (JSC-1) was used in conjunction with testing. A series of preliminary structures was constructed during final prototype design based on the principles of the classic masonry arch. The prototype was constructed of Kevlar(TM) and filled with vermiculite. The structure is free-standing, but has not yet been load tested. Future plans would be to construct higher fidelity prototypes and to conduct appropriate tests of the structure.

Smithers, G. A.↗

NASA NTRS2009

CCSDS Spacecraft Monitor and Control Mission Operations Interoperability Prototype

We are entering a new era in space exploration. Reduced operating budgets require innovative solutions to leverage existing systems to implement the capabilities of future missions. Custom solutions to fulfill mission objectives are no longer viable. Can NASA adopt international standards to reduce costs and increase interoperability with other space agencies? Can legacy systems be leveraged in a service oriented architecture (SOA) to further reduce operations costs? The Operations Technology Facility (OTF) at the Johnson Space Center (JSC) is collaborating with Deutsches Zentrum fur Luft- und Raumfahrt (DLR) to answer these very questions. The Mission Operations and Information Management Services Area (MOIMS) Spacecraft Monitor and Control (SM&C) Working Group within the Consultative Committee for Space Data Systems (CCSDS) is developing the Mission Operations standards to address this problem space. The set of proposed standards presents a service oriented architecture to increase the level of interoperability among space agencies. The OTF and DLR are developing independent implementations of the standards as part of an interoperability prototype. This prototype will address three key components: validation of the SM&C Mission Operations protocol, exploration of the Object Management Group (OMG) Data Distribution Service (DDS), and the incorporation of legacy systems in a SOA. The OTF will implement the service providers described in the SM&C Mission Operation standards to create a portal for interaction with a spacecraft simulator. DLR will implement the service consumers to perform the monitor and control of the spacecraft. The specifications insulate the applications from the underlying transport layer. We will gain experience with a DDS transport layer as we delegate responsibility to the middleware and explore transport bridges to connect disparate middleware products. A SOA facilitates the reuse of software components. The prototype will leverage the capabilities of existing legacy systems. Various custom applications and middleware solutions will be combined into one system providing the illusion of a set of homogenous services. This paper will document our journey as we implement the interoperability prototype. The team consists of software engineers with experience on the current command, telemetry and messaging systems that support the International Space Station (ISS) and Space Shuttle programs. Emphasis will be on the objectives, results and potential cost saving benefits.

Lucord, Steve↗

NASA NTRS2009

Development and Testing of a Prototype Grid-Tied Photovoltaic Power System

The NASA Glenn Research Center (GRC) has developed and tested a prototype 2 kW DC grid-tied photovoltaic (PV) power system at the Center. The PV system has generated in excess of 6700 kWh since operation commenced in July 2006. The PV system is providing power to the GRC grid for use by all. Operation of the prototype PV system has been completely trouble free. A grid-tied PV power system is connected directly to the utility distribution grid. Facility power can be obtained from the utility system as normal. The PV system is synchronized with the utility system to provide power for the facility, and excess power is provided to the utility. The project transfers space technology to terrestrial use via nontraditional partners. GRC personnel glean valuable experience with PV power systems that are directly applicable to various space power systems, and provide valuable space program test data. PV power systems help to reduce harmful emissions and reduce the Nation s dependence on fossil fuels. Power generated by the PV system reduces the GRC utility demand, and the surplus power aids the community. Present global energy concerns reinforce the need for the development of alternative energy systems. Modern PV panels are readily available, reliable, efficient, and economical with a life expectancy of at least 25 years. Modern electronics has been the enabling technology behind grid-tied power systems, making them safe, reliable, efficient, and economical with a life expectancy of at least 25 years. Based upon the success of the prototype PV system, additional PV power system expansion at GRC is under consideration. The prototype grid-tied PV power system was successfully designed and developed which served to validate the basic principles described, and the theoretical work that was performed. The report concludes that grid-tied photovoltaic power systems are reliable, maintenance free, long life power systems, and are of significant value to NASA and the community.

Eichenberg, Dennis J.↗

NASA NTRS2010

Concept, Design, and Prototyping of XSAS: A High Power Extendable Solar Array for CubeSat Applications

CubeSats have proven themselves as a reliable and cost-effective method to perform experiments in space, but they are highly constrained by their specifications and size. One such constraint is the average continuous power, about 5 W, which is available to the typical CubeSat. To improve this constraint, we have developed the eXtendable Solar Array System (XSAS), a deployable solar array prototype in a CubeSat package, which can provide an average 23 W of continuous power. The prototype served as a technology demonstrator for the high risk mechanisms needed to release, deploy, and control the solar array. Aside from this drastic power increase, it is in the integration of each mechanism, their application within the small CubeSat form-factor, and the inherent passive control benefit of the deployed geometry that make XSAS a novel design. In this paper, we discuss the requirements and design process for the XSAS system and mechanical prototype, and provide qualitative and quantitative results from numerical simulations and prototype tests. We also discuss future work, including an upcoming NASA zero-gravity flight campaign, to further improve on XSAS and prepare it for future launch opportunities.

Senatore, Patrick↗

NASA NTRS2010

Ares I-X Ground Diagnostic Prototype

The automation of pre-launch diagnostics for launch vehicles offers three potential benefits: improving safety, reducing cost, and reducing launch delays. The Ares I-X Ground Diagnostic Prototype demonstrated anomaly detection, fault detection, fault isolation, and diagnostics for the Ares I-X first-stage Thrust Vector Control and for the associated ground hydraulics while the vehicle was in the Vehicle Assembly Building at Kennedy Space Center (KSC) and while it was on the launch pad. The prototype combines three existing tools. The first tool, TEAMS (Testability Engineering and Maintenance System), is a model-based tool from Qualtech Systems Inc. for fault isolation and diagnostics. The second tool, SHINE (Spacecraft Health Inference Engine), is a rule-based expert system that was developed at the NASA Jet Propulsion Laboratory. We developed SHINE rules for fault detection and mode identification, and used the outputs of SHINE as inputs to TEAMS. The third tool, IMS (Inductive Monitoring System), is an anomaly detection tool that was developed at NASA Ames Research Center. The three tools were integrated and deployed to KSC, where they were interfaced with live data. This paper describes how the prototype performed during the period of time before the launch, including accuracy and computer resource usage. The paper concludes with some of the lessons that we learned from the experience of developing and deploying the prototype.

Schwabacher, Mark A.↗

NASA NTRS2005

Automated Rapid Prototyping of 3D Ceramic Parts

An automated system of manufacturing equipment produces three-dimensional (3D) ceramic parts specified by computational models of the parts. The system implements an advanced, automated version of a generic rapid-prototyping process in which the fabrication of an object having a possibly complex 3D shape includes stacking of thin sheets, the outlines of which closely approximate the horizontal cross sections of the object at their respective heights. In this process, the thin sheets are made of a ceramic precursor material, and the stack is subsequently heated to transform it into a unitary ceramic object. In addition to the computer used to generate the computational model of the part to be fabricated, the equipment used in this process includes: 1) A commercially available laminated-object-manufacturing machine that was originally designed for building woodlike 3D objects from paper and was modified to accept sheets of ceramic precursor material, and 2) A machine designed specifically to feed single sheets of ceramic precursor material to the laminated-object-manufacturing machine. Like other rapid-prototyping processes that utilize stacking of thin sheets, this process begins with generation of the computational model of the part to be fabricated, followed by computational sectioning of the part into layers of predetermined thickness that collectively define the shape of the part. Information about each layer is transmitted to rapid-prototyping equipment, where the part is built layer by layer. What distinguishes this process from other rapid-prototyping processes that utilize stacking of thin sheets are the details of the machines and the actions that they perform. In this process, flexible sheets of ceramic precursor material (called "green" ceramic sheets) suitable for lamination are produced by tape casting. The binder used in the tape casting is specially formulated to enable lamination of layers with little or no applied heat or pressure. The tape is cut into individual sheets, which are stacked in the sheet-feeding machine until used. The sheet-feeding machine can hold enough sheets for about 8 hours of continuous operation.

McMillin, Scott G.↗

NASA NTRS2012

Advanced Prototype Fan Operating Experience, Post Test Evaluation, and Refurbishment for PLSS 2.0 Test Use

NASA s plans for Extravehicular Activity (EVA) portable life support systems for future exploration missions result in different design requirements than those which led to the combined fan / pump / separator in the current ISS Extravehicular Mobility Unit (EMU). To meet these new requirements, NASA contracted with Hamilton Sundstrand to provide two new prototype fans designed to meet anticipated future system requirements. Based on design trade studies, a high speed fan with mechanical bearing support of the rotating elements and a novel non-metallic barrier canned motor design was developed and implemented in the deliverable prototypes. The prototypes, which used two different bearing lubricants, have been extensively tested in both stand-alone and integrated system tests in NASA laboratories and proven to meet the anticipated performance requirements. Subsequently, they have been subjected to post test inspection and analysis in Hamilton Sundstrand laboratories to assess the effects of integrated operation and resultant exposure to vent loop contaminants. Results have confirmed expectations that one of the lubricants would be superior in this application and the prototype fans have been reassembled with new bearings with the superior lubricant. They have now been returned to the Johnson Space Center for further testing and maturation as part of NASA s PLSS 2.0 integrated test effort. This paper will discuss the test history of these units, resulting test data, the results of post test evaluation, and plans for further testing in the near future.

Hodgson, Edward↗

NASA NTRS2015

Design, Fabrication, and Testing of a Composite Rack Prototype in Support of the Deep Space Habitat Program

In support of the Deep Space Habitat project a number of composite rack prototypes were developed, designed, fabricated and tested to various extents ( with the International Standard Payload Rack configuration, or crew quarters, as a baseline). This paper focuses specifically on a composite rack prototype with a direct tie in to Space Station hardware. The outlined prototype is an all composite construction, excluding metallic fasteners, washers, and their associated inserts. The rack utilizes braided carbon composite tubing for the frame with the sidewalls, backwall and flooring sections utilizing aircraft grade composite honeycomb sandwich panels. Novel additively manufactured thermoplastic joints and tube inserts were also developed in support of this effort. Joint and tube insert screening tests were conducted at a preliminary level. The screening tests allowed for modification, and enhancement, of the fabrication and design approaches, which will be outlined. The initial joint tests did not include mechanical fasteners. Adhesives were utilized at the joint to composite tube interfaces, along with mechanical fasteners during final fabrication (thus creating a stronger joint than the adhesive only variant). In general the prototype was focused on a potential in-space assembly approach, or kit-of-parts construction concept, which would not necessarily require the inclusion of an adhesive in the joint regions. However, given the tie in to legacy Station hardware (and potential flight loads with imbedded hardware mass loadings), the rack was built as stiff and strong as possible. Preliminary torque down tests were also conducted to determine the feasibility of mounting the composite honeycomb panels to the composite tubing sections via the additively manufactured tube inserts. Additional fastener torque down tests were also conducted with inserts (helicoils) imbedded within the joints. Lessons learned are also included and discussed.

Smith, Russ↗