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54 records · Page 3

Seal testing of large diameter rocket motors

This investigative program examines leakage testing of elastomeric O-ring seals for a solid rocket casing and provides direction towards an improved nondestructive postassembly test. It also details test equipment for the Space Shuttle systems solid rocket boosters (SRB). The results are useful to designers of hardware for pressure containment vessels which use O-ring seals. Using several subscale seal and groove configuration test fixtures equipped with either two or three O-ring seals in series, seal integrity is investigated with both a pressure decay and flowmeter methods. Both types of test equipment adequately detect the practical range of expected seal leak rates of 1 to 0.0001 sccs. The flowmeter leak test equipment appears to reduce testing time substantially. Limited seal leakage testing is performed on full-sized rocket motor segment seals, a pre-Challenger short stack, providing comparison of bore seals to test specimen bore and face seals. The conclusions are that seal reliability, verified via a performance pressure test, can be affected by temperature, quantity of grease, test pressure, and seal pressure load direction. Potential seal failure scenarios including contamination, seal damage, and sealing surface damage are discussed. Recommendations are made for an improved test procedure.

Moore, N. B.

Test program, helium II orbital resupply coupling

The full scope of this program was to have included development tests, design and production of custom test equipment and acceptance and qualification testing of prototype and protoflight coupling hardware. This program was performed by Ball Aerospace Systems Division, Boulder, Colorado until its premature termination in May 1991. Development tests were performed on cryogenic face seals and flow control devices at superfluid helium (He II) conditions. Special equipment was developed to allow quantified leak detection at large leak rates up to 8.4 x 10(exp -4) SCCS. Two major fixtures were developed and characterized: The Cryogenic Test Fixture (CTF) and the Thermal Mismatch Fixture (Glovebox). The CTF allows the coupling hardware to be filled with liquid nitrogen (LN2), liquid helium (LHe) or sub-cooled liquid helium when hardware flow control valves are either open or closed. Heat leak measurements, internal and external helium leakage measurements, cryogenic proof pressure tests and external load applications are performed in this fixture. Special reusable MLI closures were developed to provide repeatable installations in the CTF. The Thermal Mismatch Fixture allows all design configurations of coupling hardware to be engaged and disengaged while measuring applied forces and torques. Any two hardware components may be individually thermally preconditioned within the range of 117 deg K to 350 deg K prior to engage/disengage cycling. This verifies dimensional compatibility and operation when thermally mismatched. A clean, dry GN2 atmosphere is maintained in the fixture at all times. The first shipset of hardware was received, inspected and cycled at room temperature just prior to program termination.

Hyatt, William S.

Vestibular convergence patterns in vestibular nuclei neurons of alert primates

Sensory signal convergence is a fundamental and important aspect of brain function. Such convergence may often involve complex multidimensional interactions as those proposed for the processing of otolith and semicircular canal (SCC) information for the detection of translational head movements and the effective discrimination from physically congruent gravity signals. In the present study, we have examined the responses of primate rostral vestibular nuclei (VN) neurons that do not exhibit any eye movement-related activity using 0.5-Hz translational and three-dimensional (3D) rotational motion. Three distinct neural populations were identified. Approximately one-fourth of the cells exclusively encoded rotational movements (canal-only neurons) and were unresponsive to translation. The canal-only central neurons encoded head rotation in SCC coordinates, exhibited little orthogonal canal convergence, and were characterized with significantly higher sensitivities to rotation as compared to primary SCC afferents. Another fourth of the neurons modulated their firing rates during translation (otolith-only cells). During rotations, these neurons only responded when the axis of rotation was earth-horizontal and the head was changing orientation relative to gravity. The remaining one-half of VN neurons were sensitive to both rotations and translations (otolith + canal neurons). Unlike primary otolith afferents, however, central neurons often exhibited significant spatiotemporal (noncosine) tuning properties and a wide variety of response dynamics to translation. To characterize the pattern of SCC inputs to otolith + canal neurons, their rotational maximum sensitivity vectors were computed using exclusively responses during earth-vertical axis rotations (EVA). Maximum sensitivity vectors were distributed throughout the 3D space, suggesting strong convergence from multiple SCCs. These neurons were also tested with earth-horizontal axis rotations (EHA), which would activate both vertical canals and otolith organs. However, the recorded responses could not be predicted from a linear combination of EVA rotational and translational responses. In contrast, one-third of the neurons responded similarly during EVA and EHA rotations, although a significant response modulation was present during translation. Thus this subpopulation of otolith + canal cells, which included neurons with either high- or low-pass dynamics to translation, appear to selectively ignore the component of otolith-selective activation that is due to changes in the orientation of the head relative to gravity. Thus contrary to primary otolith afferents and otolith-only central neurons that respond equivalently to tilts relative to gravity and translational movements, approximately one-third of the otolith + canal cells seem to encode a true estimate of the translational component of the imposed passive head and body movement.

Non-NASA Center

Creating and Testing Simulation Software

The goal of this project is to learn about the software development process, specifically the process to test and fix components of the software. The paper will cover the techniques of testing code, and the benefits of using one style of testing over another. It will also discuss the overall software design and development lifecycle, and how code testing plays an integral role in it. Coding is notorious for always needing to be debugged due to coding errors or faulty program design. Writing tests either before or during program creation that cover all aspects of the code provide a relatively easy way to locate and fix errors, which will in turn decrease the necessity to fix a program after it is released for common use. The backdrop for this paper is the Spaceport Command and Control System (SCCS) Simulation Computer Software Configuration Item (CSCI), a project whose goal is to simulate a launch using simulated models of the ground systems and the connections between them and the control room. The simulations will be used for training and to ensure that all possible outcomes and complications are prepared for before the actual launch day. The code being tested is the Programmable Logic Controller Interface (PLCIF) code, the component responsible for transferring the information from the models to the model Programmable Logic Controllers (PLCs), basic computers that are used for very simple tasks.

Heinich, Christina M.

Design and Development of Functionally Operative and Visually Appealing Remote Firing Room Displays

This internship provided an opportunity for an intern to work with NASA's Ground Support Equipment (GSE) for the Spaceport Command and Control System (SCCS) at Kennedy Space Center as a remote display developer, under NASA mentor Kurt Leucht. The main focus was on creating remote displays for the hypergolic and high pressure helium subsystem team to help control the filling of the respective tanks. As a remote display developer for the GSE hypergolic and high pressure helium subsystem team the intern was responsible for creating and testing graphical remote displays to be used in the Launch Control Center (LCC) on the Firing Room's computer monitors. To become more familiar with the subsystem, the individual attended multiple project meetings and acquired their specific requirements regarding what needed to be included in the remote displays. After receiving the requirements, the next step was to create a display that had both visual appeal and logical order using the Display Editor, on the Virtual Machine (VM). In doing so, all Compact Unique Identifiers (CUI), which are associated with specific components within the subsystem, will need to be included in each respective display for the system to run properly. Then, once the display was created it needed to be tested to ensure that the display runs as intended by using the Test Driver, also found on the VM. This Test Driver is a specific application that checks to make sure all the CUIs in the display are running properly and returning the correct form of information. After creating and locally testing the display it will need to go through further testing and evaluation before deemed suitable for actual use. By the end of the semester long experience at NASA's Kennedy Space Center, the individual should have gained great knowledge and experience in various areas of display development and testing. They were able to demonstrate this new knowledge obtained by creating multiple successful remote displays that will one day be used by the hypergolic and high pressure helium subsystem team in one of the LCC's firing rooms to fill the new Orion spacecraft.

Ground Support Systems

Development and Testing of Functionally Operative and Visually Appealing Remote Firing Room Displays and Applications

This internship provided an opportunity for an intern to work with NASA's Ground Support Equipment (GSE) for the Spaceport Command and Control System (SCCS) at Kennedy Space Center as a remote display developer, under NASA technical mentor Kurt Leucht. The main focus was on creating remote displays and applications for the hypergolic and high pressure helium subsystem team to help control the filling of the respective tanks. As a remote display and application developer for the GSE hypergolic and high pressure helium subsystem team the intern was responsible for creating and testing graphical remote displays and applications to be used in the Launch Control Center (LCC) on the Firing Room's computers. To become more familiar with the subsystem, the individual attended multiple project meetings and acquired their specific requirements regarding what needed to be included in the software. After receiving the requirements for the displays, the next step was to create displays that had both visual appeal and logical order using the Display Editor, on the Virtual Machine (VM). In doing so, all Compact Unique Identifiers (CUI), which are associated with specific components within the subsystem, were need to be included in each respective display for the system to run properly. Then, once the display was created it was to be tested to ensure that the display runs as intended by using the Test Driver, also found on the VM. This Test Driver is a specific application that checks to make sure all the CUIs in the display are running properly and returning the correct form of information. After creating and locally testing the display it needed to go through further testing and evaluation before deemed suitable for actual use. For the remote applications the intern was responsible for creating a project that focused on channelizing each component included in each display. The core of the application code was created by setting up spreadsheets and having an auto test generator, generate the complete code structure. This application code was then loaded and ran on a testing environment set to ensure the code runs as anticipated. By the end of the semester-long experience at NASA's Kennedy Space Center, the individual should have gained great knowledge and experience in various areas of both display and application development and testing. They were able to demonstrate this new knowledge obtained by creating multiple successful remote displays that will one day be used by the hypergolic and high pressure helium subsystem team in the LCC's firing rooms to service the new Orion spacecraft. The completed display channelization application will be used to receive verification from NASA quality engineers.

Display Devices

Simscape Modeling Verification in the Simulink Development Environment

The purpose of the Simulation Product Group of the Control and Data Systems division of the NASA Engineering branch at Kennedy Space Center is to provide a realtime model and simulation of the Ground Subsystems participating in vehicle launching activities. The simulation software is part of the Spaceport Command and Control System (SCCS) and is designed to support integrated launch operation software verification, and console operator training. Using Mathworks Simulink tools, modeling engineers currently build models from the custom-built blocks to accurately represent ground hardware. This is time consuming and costly due to required rigorous testing and peer reviews to be conducted for each custom-built block. Using Mathworks Simscape tools, modeling time can be reduced since there would be no custom-code developed. After careful research, the group came to the conclusion it is feasible to use Simscape's blocks in MatLab's Simulink. My project this fall was to verify the accuracy of the Crew Access Arm model developed using Simscape tools running in the Simulink development environment.

SIMSCAPE

Supporting Multiple Programs and Projects at NASA's Kennedy Space Center

With the conclusion of the shuttle program in 2011, the National Aeronautics and Space Administration (NASA) had found itself at a crossroads for finding transportation of United States astronauts and experiments to space. The agency would eventually hand off the taxiing of American astronauts to the International Space Station (ISS) that orbits in Low Earth Orbit (LEO) about 210 miles above the earth under the requirements of the Commercial Crew Program (CCP). By privatizing the round trip journey from Earth to the ISS, the space agency has been given the additional time to focus funding and resources to projects that operate beyond LEO; however, adding even more stress to the agency, the premature cancellation of the program that would succeed the Shuttle Program - The Constellation Program (CxP) -it would inevitably delay the goal to travel beyond LEO for a number of years. Enter the Space Launch System (SLS) and the Orion Multipurpose Crew Vehicle (MPCV). Currently, the SLS is under development at NASA's Marshall Spaceflight Center in Huntsville, Alabama, while the Orion Capsule, built by government contractor Lockheed Martin Corporation, has been assembled and is currently under testing at the Kennedy Space Center (KSC) in Florida. In its current vision, SLS will take Orion and its crew to an asteroid that had been captured in an earlier mission in lunar orbit. Additionally, this vehicle and its configuration is NASA's transportation to Mars. Engineers at the Kennedy Space Center are currently working to test the ground systems that will facilitate the launch of Orion and the SLS within its Ground Services Development and Operations (GSDO) Program. Firing Room 1 in the Launch Control Center (LCC) has been refurbished and outfitted to support the SLS Program. In addition, the Spaceport Command and Control System (SCCS) is the underlying control system for monitoring and launching manned launch vehicles. As NASA finds itself at a junction, so does all of its associated centers across the US. KSC has found itself at the blunt end of change as the entire center has transitioned from an operations mindset to a development mentality. The author of this paper has had the fortunate privilege and opportunity to be part of a transforming NASA during the fall months of 2014. The following is a high level account of projects that he had the chance to work on including the Spaceport Command and Control System, the Advanced Ground System and Maintenance Program Project, Customer Avionics Development & Analysis (CAIDA) Lab and Swamp Works.

Advanced Ground System Maintenance

Spaceport Command and Control System - Support Software Development

The Information Architecture Support (IAS) Team, the component of the Spaceport Command and Control System (SCCS) that is in charge of all the pre-runtime data, was in need of some report features to be added to their internal web application, Information Architecture (IA). Development of these reports is crucial for the speed and productivity of the development team, as they are needed to quickly and efficiently make specific and complicated data requests against the massive IA database. These reports were being put on the back burner, as other development of IA was prioritized over them, but the need for them resulted in internships being created to fill this need. The creation of these reports required learning Ruby on Rails development, along with related web technologies, and they will continue to serve IAS and other support software teams and their IA data needs.

Information Architecture

Spaceport Command and Control System Software Development

The Spaceport Command and Control System (SCCS) is the National Aeronautics and Space Administration's (NASA) launch control system for the Orion capsule and Space Launch System, the next generation manned rocket currently in development. This large system requires a large amount of intensive testing that will properly measure the capabilities of the system. Automating the test procedures would save the project money from human labor costs, as well as making the testing process more efficient. Therefore, the Exploration Systems Division (formerly the Electrical Engineering Division) at Kennedy Space Center (KSC) has recruited interns for the past two years to work alongside full-time engineers to develop these automated tests, as well as innovate upon the current automation process.

Glasser, Abraham

Database Tool for Master Console Operators

The Spaceport Command and Control System (SCCS) is the National Aeronautics and Space Administration's (NASA) launch control system for the Orion capsule and Space Launch System, the next generation manned rocket currently in development. This large system requires highly trained and knowledgeable personnel. Master Console Operators (MCO) are currently working on familiarizing themselves with any possible scenario that they may encounter. An intern was recruited to help assist them with creating a tool to use for the process.

Ferrell, Sean

Interoperable End-To-End Space Communications Architecture Using CCSDS Building Blocks

End-to-end space communication architectures must connect system elements that may be in space, on the ground in mission operations centers, or are shared assets such as ground communications stations. End-to-end connectivity involves space communications over RF links, but also cross support services, terrestrial network circuits, and a variety of application layer protocols for commanding, telemetry, and mission operations. CCSDS has developed a large suite of interoperable, and cross-supportable, protocols for these purposes. Each of these defines a specific “layer” of functionality, such as: RF modulation, space link error coding, cross support frame delivery, or network layer routing. CCSDS has recently published a Space Communication Cross Support Architecture Requirements Document (SCCS-ARD) that describes how many of these standards fit together and how they are intended to be used. This paper provides an overview of this document, presented so as to explain the concepts so that others may use them. These concepts will be described from several key viewpoints.

Shames, Peter M.

Interoperable End-To-End Space Communications Architectures Using CCSDS Building Blocks

End-to-end space communication architectures must connect system elements that may be in space, on the ground in mission operations centers, or are shared assets such as ground communications stations. End-to-end connectivity involves space communications over RF links, but also cross support services, terrestrial network circuits, and a variety of application layer protocols for commanding, telemetry, and mission operations. CCSDS has developed a large suite of interoperable, and cross-supportable, protocols for these purposes. Each of these defines a specific “layer” of functionality, such as: RF modulation, space link error coding, cross support frame delivery, or network layer routing. CCSDS has recently published a Space Communication Cross Support Architecture Requirements Document (SCCS-ARD) that describes how many of these standards fit together and how they are intended to be used. This paper provides an overview of this document, presented so as to explain the concepts so that others may use them. These concepts will be described from several key viewpoints.

Shames, Peter M.

On the Equivalence of Gas and Liquid Leak Flow Rates for Application to Propulsion and Propellant Transfer Systems

The equivalence of leak rates for gas flow and liquid flow through an arbitrary small leak size in pressurized systems has been investigated theoretically and experimentally. Measurements were taken for gaseous helium (GHe) rates and water flow issuing from the same leak configuration. The predictions for the correlation of GHe leak rates to water leak rates have been satisfactorily compared with present test data and those of other investigators over a wide range leak flow rates (many orders of magnitude) corresponding to a wide range of leak sizes (0.1 m to 0.1 mm). The results show that at extremely small leak sizes (sub-micron range), the effects of Knudsen number in the free molecular regime (rarefied gases) become important. By a proper scaling procedure, the measured flow rate for water could be applied to equivalent propellant leaks in flight operations. In the present tests the micro-channel range of the leak size is satisfactorily simulated by repeatable precision set needle position valve. Test results show that in general the theoretical model predicts the data reasonably well for GHe flow rates in the range of 0.001 to 1 sccs. Outside this range of GHe flow rates some adjustments (improvements) to the analytical model are required along with further testing.

Max Kandula

Fitting Leak Test Report: Ground-Based Cryogenic Leak Test of Fittings for Cryogenic Fluid Management

EXECUTIVE SUMMARY Mechanically connected joints used in cryogenic fluid lines as part of space flight elements need to survive launch vibrations and remain leak-free to minimize the loss of on-board commodity and hazardous gas accumulation. In 2020, a cryogenic test apparatus was developed which can evaluate the leak performance of pressurized threaded fluid fittings. The fittings were mounted in the TVAC and cooled to cryogenic test temperature and pressurized with helium while the leak rate was measured using a calibrated GHe leak detector. The test articles for the initial proof of concept testing were ¼ and 1 inch Swagelok VCR fittings with three different types of seal rings copper, nickel, and Ni. Each fitting configuration (size/seal material) was subjected to two consecutive cryogenic thermal cycles, followed by exposure to a launch vibration profile at ambient temperature, after which two additional TVAC cycle tests were performed. The testing reported here is a continuation of the 2020 tests with a statistically significant large number of samples and test runs. Three Swagelok VCR fitting sizes were tested ¼, ½ and 1 inch, and five (5) samples of each fitting size, each sample was tested with SST and Ni seal rings (Total of 30 unique test articles). Each test article was subjected to four (4) thermal cycles. Half of these cycles were performed before vibration testing and half were performed after vibration testing. The vibration testing was performed to evaluate the ability of the fittings to survive launch-type vibration profiles and remain leak-free. Leak checking of each fitting was completed at temperatures between 20K – 30K. The test procedure in Section 8.0 was designed to facilitate a qualification test program by allowing a higher test throughput rate coupled with repeatable test profiles. Results were very positive and show that out of the 30 samples they all passed with leak rates a factor of 2-3 lower than the established 10-6sccs GHe leak threshold. The result showed the Ni seals had lower leak rate, but the SST was more rugged. There were two deviations where damage to the Ni seal ring during assembly resulted in a leaky fitting, this is discussed in Section 10.7 Test Deviations. These fittings show great promise for space flight use and further testing is recommended to fully qualify the fittings per the ASTM F1387-19 and/or other relevant NASA specifications. The test equipment hardware and software capability developed for this testing is generic and not restricted to VCR fittings. It can be employed to evaluate/qualify the leak performance of other types of fittings and a wide range of other cryogenic fluid components such as valves, gages, connectors, etc.

Cryogenic

Master Console, SMC

The Master Console oversees the function of Computer Systems in Firing room 1 (FR1). Master Console Operators, MCOs' for short, are our customer. I was integrated into the System Monitoring and Control (SMC) software team that is under the guidance of David Slaiman, who is the product group lead. I have been brought up to speed with System Monitoring and Control. The initial time spent reading SMC software design description and understanding how it works. The current Firing Room 1 Console Display is a floor layout giving the MCO two essential pieces of information which are Health and Status. When an issue arises, the MCO has to look on the display to find which console is affected and then the MCO must use the Reference designator from the display to manually search for the Portal Workstation (PWS) installed in the console using the hardware map; which is a long process to lookup a PWS if an issue is present. My project is to make the FR1 Console Display easier for the MCO's to pinpoint PWS's without having to lookup additional resources in the process. My project also includes updating Firing Room 1 Console Display to include the F1R Non-Redundant Set. The display does not have good use of space and functionality. PWS numbers were not present in the previous design and are the critical component in efficient understanding and administration of the consoles. Part of the process includes getting feedback from the customer, instead of just emailing them with a question, we made a proposal with changes so they could respond and give us their input; which proved to be an effective method for engaging them. In order to do this I had to use the Display Editor (DE) tool developed by NASA, Paint.Net and Visio. The process I have been using has been Visio to alter the floor layout of Firing Room and take advantage of the white areas, and then I take the altered floor plan into Paint.Net. Once in Paint.Net I put the new floor plan as a background to the standard console display. Paint.Net also serves as a tool to create the new service state bars for the new background; finally I used the DE to assemble everything and setup the right CUI's for each PWS.

MCO

Spaceport Command and Control System User Interface Testing

The Spaceport Command and Control System will be the National Aeronautics and Space Administration's newest system for launching commercial and government owned spacecraft. It's a large system with many parts all in need of testing. To improve upon testing already done by NASA engineers, the Engineering Directorate, Electrical Division (NE-E) of Kennedy Space Center has hired a group of interns each of the last few semesters to develop novel ways of improving the testing process.

SCCS

Spaceport Command and Control System Software Development

There is an immense challenge in organizing personnel across a large agency such as NASA, or even over a subset of that, like a center's Engineering directorate. Workforce inefficiencies and challenges are bound to grow over time without oversight and management. It is also not always possible to hire new employees to fill workforce gaps, therefore available resources must be utilized more efficiently. The goal of this internship was to develop software that improves organizational efficiency by aiding managers, making employee information viewable and editable in an intuitive manner. This semester I created an application for managers that aids in optimizing allocation of employee resources for a single division with the possibility of scaling upwards. My duties this semester consisted of developing frontend and backend software to complete this task. The application provides user-friendly information displays and documentation of the workforce to allow NASA to track diligently track the status and skills of its workforce. This tool should be able to prove that current employees are being effectively utilized and if new hires are necessary to fulfill skill gaps.

SCCS