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Constellation Space Suit System Development Status

The Constellation Program has initiated the first new flight suit development project since the Extravehicular Mobility Unit (EMU) was developed for the Space Shuttle Program in the 1970s. The Constellation suit system represents a significant challenge to designers in that the system is required to address all space suit functions needed through all missions and mission phases. This is in marked contrast to the EMU, which was designed specifically for micro-gravity space walks. The Constellation suit system must serve in all of the following scenarios: launch, entry and abort crew survival; micro-gravity extravehicular activity (EVA); and lunar (1/6th-gravity) surface EVA. This paper discusses technical efforts performed from May 2006 through February 2007 for the Constellation space suit system pressure garment.

Ross, Amy↗

Spacecraft Water Exposure Guidelines (SWEGs)

As the protection of crew health is a primary focus of the National Aeronautics and Space Administration, the Space and Life Sciences Directorate (SLSD) is vigilant in setting potable water limits for spaceflight that are health protective. Additional it is important that exposure limits not be set so stringently that water purification systems are unnecessarily over designed. With these considerations in mind, NASA has partnered with the National Research Council on Toxicology (NRCCOT) to develop spacecraft water exposure guidelines (SWEGs) for application in spaceflight systems. Based on documented guidance (NRC, 2000) NASA has established 28 SWEGs for chemical components that are particularly relevant to water systems on the International Space Station, the Shuttle and looking forward to Constellation.

John T James↗

NASA Materials Research for Extreme Conditions

This Technical Memorandum briefly covers various innovations in materials science and development throughout the course of the American Space program. It details each innovation s discovery and development, explains its significance, and describes the applications of this material either in the time period discovered or today. Topics of research include silazane polymers, solvent-resistant elastomeric polymers (polyurethanes and polyisocyanurates), siloxanes, the Space Shuttle thermal protection system, phenolic-impregnated carbon ablator, and carbon nanotubes. Significance of these developments includes the Space Shuttle, Apollo programs, and the Constellation program.

Sharpe, R. J.↗

Global Environmental Micro Sensors Test Operations in the Natural Environment

ENSCO, Inc. is developing an innovative atmospheric observing system known as Global Environmental Micro Sensors (GEMS). The GEMS concept features an integrated system of miniaturized in situ, airborne probes measuring temperature, relative humidity, pressure, and vector wind velocity. In order for the probes to remain airborne for long periods of time, their design is based on a helium-filled super-pressure balloon. The GEMS probes are neutrally buoyant and carried passively by the wind at predetermined levels. Each probe contains onboard satellite communication, power generation, processing, and geolocation capabilities. ENSCO has partnered with the National Aeronautics and Space Administration's Kennedy Space Center (KSC) for a project called GEMS Test Operations in the Natural Environment (GEMSTONE) that will culminate with limited prototype flights of the system in spring 2007. By leveraging current advances in micro and nanotechnology, the probe mass, size, cost, and complexity can be reduced substantially so that large numbers of probes could be deployed routinely to support ground, launch, and landing operations at KSC and other locations. A full-scale system will improve the data density for the local initialization of high-resolution numerical weather prediction systems by at least an order of magnitude and provide a significantly expanded in situ data base to evaluate launch commit criteria and flight rules. When applied to launch or landing sites, this capability will reduce both weather hazards and weather-related scrubs, thus enhancing both safety and cost-avoidance for vehicles processed by the Shuttle, Launch Services Program, and Constellation Directorates. The GEMSTONE project will conclude with a field experiment in which 10 to 15 probes are released over KSC in east central Florida. The probes will be neutrally buoyant at different altitudes from 500 to 3000 meters and will report their position, speed, heading, temperature, humidity, and pressure via satellite. The GEMS data will be validated against reference observations provided by current weather instrumentation located at KSC. This paper will report on the results of the GEMSTONE project and discuss the challenges encountered in developing an airborne sensor system.

Adams, Mark L.↗

Defining the Natural Atmospheric Environment Requirements for the NASA Constellation Program

The National Aeronautics and Space Administration began developing a new vehicle under the Constellation Program to replace the Space Shuttle. The Ares-1 launch vehicle and the Orion capsule will be used to ferry crew and some payloads to the International Space Station and will also be used for new missions to the moon, As development of this new vehicle begins, the Natural Environments Branch at Marshall Space Flight Center has been tasked with defining the natural environments the vehicle will encounter and working with the program to develop natural environmental requirements for the vehicles' elements. An overview of the structure of the program is given, along with a description of the Constellation Design Specification for Natural Environments and the Constellation Natural Environments Definition for Design documents and how they apply to the Ares-I and Orion vehicles.

Roberts, Barry C.↗

Developmental Flight Instrumentation: Review of Space Shuttle, Ares I-X, and Artemis I

Ascent vehicles in the developmental stages of the program are instrumented with Developmental Flight Instrumentation (DFI) sensors. These sensors establish a link between a vehicle and engineers on the ground to communicate conditions experienced during the ascent. These data are then compared to pre-flight predictions used in the design process. The aerodynamic, acoustic, thermal, and structural data are either telemetered to ground stations during the ascent or stored on the vehicle for post-flight recovery and archived at the Huntsville Operations Support Center (HOSC). Following NASA's Artemis I Space Launch System (SLS) launch on November 16, 2020, data from three separate programs are available at the HOSC: Space Shuttle Program (Space Transport System (STS)), Constellation Program (Ares I-X), and Artemis Program (SLS). Availability of these data presents a unique opportunity to examine DFI data from three distinct vehicles and analyze the broad impact of the DFI data on the understanding of transonic aerodynamics. Classical spectrogram and Empirical Mode Decomposition techniques were used to present data in aerodynamically analogous regions on each vehicle. On the SLS and Ares I-X, a region downstream of the Launch Abort System motors was chosen. Comparing SLS and the STS, a region downstream of booster Froward Attach Hardware was selected as analogous flow region. Some other regions of interest were also identified. Although similarities in flow features on three vehicles were identified, some challenges in the comparison were also encountered, especially due to poor temporal and spatial resolution of Shuttle measurements.

Space Shuttle↗

Developmental Flight Instrumentation: Review of Space Shuttle, Ares I-X, and Artemis I

Ascent vehicles in the developmental stages of the program are instrumented with Developmental Flight Instrumentation (DFI) sensors. These sensors establish a link between a vehicle and engineers on the ground to communicate conditions experienced during the ascent. These data are then compared to pre-flight predictions used in the design process. The aerodynamic, acoustic, thermal, and structural data are either telemetered to ground stations during the ascent or stored on the vehicle for post-flight recovery and archived at the Huntsville Operations Support Center (HOSC). Following NASA's Artemis I Space Launch System (SLS) launch on November 16, 2020, data from three separate programs are available at the HOSC: Space Shuttle Program (Space Transport System (STS)), Constellation Program (Ares I-X), and Artemis Program (SLS). Availability of these data presents a unique opportunity to examine DFI data from three distinct vehicles and analyze the broad impact of the DFI data on the understanding of transonic aerodynamics. Classical spectrogram and Empirical Mode Decomposition techniques were used to present data in aerodynamically analogous regions on each vehicle. On the SLS and Ares I-X, a region downstream of the Launch Abort System motors was chosen. Comparing SLS and the STS, a region downstream of booster Froward Attach Hardware was selected as analogous flow region. Some other regions of interest were also identified. Although similarities in flow features on three vehicles were identified, some challenges in the comparison were also encountered, especially due to poor temporal and spatial resolution of Shuttle measurements.

Space Shuttle↗

NASA Perspective on Requirements for Development of Advanced Methods Predicting Unsteady Aerodynamics and Aeroelasticity

Over the past three years, the National Aeronautics and Space Administration (NASA) has initiated design, development, and testing of a new human-rated space exploration system under the Constellation Program. Initial designs within the Constellation Program are scheduled to replace the present Space Shuttle, which is slated for retirement within the next three years. The development of vehicles for the Constellation system has encountered several unsteady aerodynamics challenges that have bearing on more traditional unsteady aerodynamic and aeroelastic analysis. This paper focuses on the synergy between the present NASA challenges and the ongoing challenges that have historically been the subject of research and method development. There are specific similarities in the flows required to be analyzed for the space exploration problems and those required for some of the more nonlinear unsteady aerodynamic and aeroelastic problems encountered on aircraft. The aggressive schedule, significant technical challenge, and high-priority status of the exploration system development is forcing engineers to implement existing tools and techniques in a design and application environment that is significantly stretching the capability of their methods. While these methods afford the users with the ability to rapidly turn around designs and analyses, their aggressive implementation comes at a price. The relative immaturity of the techniques for specific flow problems and the inexperience with their broad application to them, particularly on manned spacecraft flight system, has resulted in the implementation of an extensive wind tunnel and flight test program to reduce uncertainty and improve the experience base in the application of these methods. This provides a unique opportunity for unsteady aerodynamics and aeroelastic method developers to test and evaluate new analysis techniques on problems with high potential for acquisition of test and even flight data against which they can be evaluated. However, researchers may be required to alter the geometries typically used in their analyses, the types of flows analyzed, and even the techniques by which computational tools are verified and validated. This paper discusses these issues and provides some perspective on the potential for new and innovative approaches to the development of methods to attack problems in nonlinear unsteady aerodynamics.

Schuster, David M.↗

Failure Analysis at the Kennedy Space Center

History has shown that failures occur in every engineering endeavor, and what we learn from those failures contributes to the knowledge base to safely complete future missions. The necessity of failure analysis is at its apex at the end of one aged program (i.e. Shuttle) and at the beginning of a new and untested program (i.e. Constellation). The information that we gain through failure analysis corrects the deficiencies in the current vehicle to make the next generation of vehicles more efficient and safe. The Failure Analysis and Materials Evaluation section in the Materials Science Division at the Kennedy Space Center performs metallurgical, mechanical, electrical, and non-metallic failure analysis and accident investigations on both flight hardware and ground support equipment (GSE) for the Shuttle, International Space Station, Constellation, and Launch Services Programs. This presentation will explore a variety of failure case studies at KSC and the lessons learned that can be applied in future programs.

Salazar, Victoria L.↗

Apollo: Learning From the Past, For the Future

This paper shares an interesting and unique case study of knowledge capture by the National Aeronautics and Space Administration (NASA), an ongoing project to recapture and make available the lessons learned from the Apollo lunar landing project so that those working on future projects do not have to "reinvent the wheel". NASA's new Constellation program, the successor to the Space Shuttle program, proposes a return to the Moon using a new generation of vehicles. The Orion Crew Vehicle and the Altair Lunar Lander will use hardware, practices, and techniques descended and derived from Apollo, Shuttle and the International Space Station. However, the new generation of engineers and managers who will be working with Orion and Altair are largely from the decades following Apollo, and are likely not well aware of what was developed in the 1960s. In 2006 a project at NASA's Johnson Space Center was begun to find pertinent Apollo-era documentation and gather it, format it, and present it using modern tools for today's engineers and managers. This "Apollo Mission Familiarization for Constellation Personnel" project is accessible via the web from any NASA center for those interested in learning "how did we do this during Apollo?"

Grabois, Michael R.↗

Apollo: Learning From the Past, For the Future

This paper shares an interesting and unique case study of knowledge capture by the National Aeronautics and Space Administration (NASA), an ongoing project to recapture and make available the lessons learned from the Apollo lunar landing project so that those working on future projects do not have to "reinvent the wheel". NASA's new Constellation program, the successor to the Space Shuttle program, proposes a return to the Moon using a new generation of vehicles. The Orion Crew Vehicle and the Altair Lunar Lander will use hardware, practices, and techniques descended and derived from Apollo, Shuttle and the International Space Station. However, the new generation of engineers and managers who will be working with Orion and Altair are largely from the decades following Apollo, and are likely not well aware of what was developed in the 1960s. In 2006 a project at NASA's Johnson Space Center was begun to find pertinent Apollo-era documentation and gather it, format it, and present it using modern tools for today's engineers and managers. This "Apollo Mission Familiarization for Constellation Personnel" project is accessible via the web from any NASA center for those interested in learning "how did we do this during Apollo?"

Grabois, Michael R.↗

Structural requirements and technology needs of geostationary platforms

To identify structural requirements and technology needs of the geostationary platforms, two design alternatives are analyzed with respect to utilities accommodation, interface, and strength and stiffness requirements. Alternative 1 is comprised of 6,800 kg (15,000 lb) platform modules, each delivered to low earth orbit (LEO) with an attached orbit transfer vehicle (OTV) in a single Shuttle flight, deployed, and transferred to a geostationary constellation of platforms. Alternative 2 is made up of 16,800 kg (37,000 lb) platform modules, each delivered to LEO, deployed, mated to a 2 stage OTV (delivered to LEO in two additional Shuttle flights) and transferred to GEO for docking with other modules to form a single large platform. The top candidates for deployable structure elements are the expandable truss beam and the Astromast. The beam, fabricated of graphite/epoxy with a designed coefficient of thermal expansion of zero, provides good packaging density and high strength and stiffness per unit weight. The Astromast provides the best packaging density, but lacks the strength and stiffness required for the platform payloads. A graphite/epoxy mast with the Astromast packaging density is an advancement in technology needed for optimizing the geostationary platform designs.

Stone, G. R.↗

General Purpose Data-Driven Monitoring for Space Operations

As modern space propulsion and exploration systems improve in capability and efficiency, their designs are becoming increasingly sophisticated and complex. Determining the health state of these systems, using traditional parameter limit checking, model-based, or rule-based methods, is becoming more difficult as the number of sensors and component interactions grow. Data-driven monitoring techniques have been developed to address these issues by analyzing system operations data to automatically characterize normal system behavior. System health can be monitored by comparing real-time operating data with these nominal characterizations, providing detection of anomalous data signatures indicative of system faults or failures. The Inductive Monitoring System (IMS) is a data-driven system health monitoring software tool that has been successfully applied to several aerospace applications. IMS uses a data mining technique called clustering to analyze archived system data and characterize normal interactions between parameters. The scope of IMS based data-driven monitoring applications continues to expand with current development activities. Successful IMS deployment in the International Space Station (ISS) flight control room to monitor ISS attitude control systems has led to applications in other ISS flight control disciplines, such as thermal control. It has also generated interest in data-driven monitoring capability for Constellation, NASA's program to replace the Space Shuttle with new launch vehicles and spacecraft capable of returning astronauts to the moon, and then on to Mars. Several projects are currently underway to evaluate and mature the IMS technology and complementary tools for use in the Constellation program. These include an experiment on board the Air Force TacSat-3 satellite, and ground systems monitoring for NASA's Ares I-X and Ares I launch vehicles. The TacSat-3 Vehicle System Management (TVSM) project is a software experiment to integrate fault and anomaly detection algorithms and diagnosis tools with executive and adaptive planning functions contained in the flight software on-board the Air Force Research Laboratory TacSat-3 satellite. The TVSM software package will be uploaded after launch to monitor spacecraft subsystems such as power and guidance, navigation, and control (GN&C). It will analyze data in real-time to demonstrate detection of faults and unusual conditions, diagnose problems, and react to threats to spacecraft health and mission goals. The experiment will demonstrate the feasibility and effectiveness of integrated system health management (ISHM) technologies with both ground and on-board experiments.

Iverson, David L.↗

Evolution of the Space Shuttle Primary Avionics Software and Avionics for Shuttle Derived Launch Vehicles

As a result of recommendation from the Augustine Panel, the direction for Human Space Flight has been altered from the original plan referred to as Constellation. NASA s Human Exploration Framework Team (HEFT) proposes the use of a Shuttle Derived Heavy Lift Launch Vehicle (SDLV) and an Orion derived spacecraft (salvaged from Constellation) to support a new flexible direction for space exploration. The SDLV must be developed within an environment of a constrained budget and a preferred fast development schedule. Thus, it has been proposed to utilize existing assets from the Shuttle Program to speed development at a lower cost. These existing assets should not only include structures such as external tanks or solid rockets, but also the Flight Software which has traditionally been a "long pole" in new development efforts. The avionics and software for the Space Shuttle was primarily developed in the 70 s and considered state of the art for that time. As one may argue that the existing avionics and flight software may be too outdated to support the new SDLV effort, this is a fallacy if they can be evolved over time into a "modern avionics" platform. The technology may be outdated, but the avionics concepts and flight software algorithms are not. The reuse of existing avionics and software also allows for the reuse of development, verification, and operations facilities. The keyword is evolve in that these assets can support the fast development of such a vehicle, but then be gradually evolved over time towards more modern platforms as budget and schedule permits. The "gold" of the flight software is the "control loop" algorithms of the vehicle. This is the Guidance, Navigation, and Control (GNC) software algorithms. This software is typically the most expensive to develop, test, and verify. Thus, the approach is to preserve the GNC flight software, while first evolving the supporting software (such as Command and Data Handling, Caution and Warning, Telemetry, etc.). This can be accomplished by gradually removing the "support software" from the legacy flight software leaving only the GNC algorithms. The "support software" could be re-developed for modern platforms, while leaving the GNC algorithms to execute on technology compatible with the legacy system. It is also possible to package the GNC algorithms into an emulated version of the original computer (via Field Programmable Gate Arrays or FPGAs), thus becoming a "GNC on a Chip" solution where it could live forever to be embedded in modern avionics platforms.

Ferguson, Roscoe C.↗

Constellation Program Life-cycle Cost Analysis Model (LCAM)

The Constellation Program (CxP) is NASA's effort to replace the Space Shuttle, return humans to the moon, and prepare for a human mission to Mars. The major elements of the Constellation Lunar sortie design reference mission architecture are shown. Unlike the Apollo Program of the 1960's, affordability is a major concern of United States policy makers and NASA management. To measure Constellation affordability, a total ownership cost life-cycle parametric cost estimating capability is required. This capability is being developed by the Constellation Systems Engineering and Integration (SE&I) Directorate, and is called the Lifecycle Cost Analysis Model (LCAM). The requirements for LCAM are based on the need to have a parametric estimating capability in order to do top-level program analysis, evaluate design alternatives, and explore options for future systems. By estimating the total cost of ownership within the context of the planned Constellation budget, LCAM can provide Program and NASA management with the cost data necessary to identify the most affordable alternatives. LCAM is also a key component of the Integrated Program Model (IPM), an SE&I developed capability that combines parametric sizing tools with cost, schedule, and risk models to perform program analysis. LCAM is used in the generation of cost estimates for system level trades and analyses. It draws upon the legacy of previous architecture level cost models, such as the Exploration Systems Mission Directorate (ESMD) Architecture Cost Model (ARCOM) developed for Simulation Based Acquisition (SBA), and ATLAS. LCAM is used to support requirements and design trade studies by calculating changes in cost relative to a baseline option cost. Estimated costs are generally low fidelity to accommodate available input data and available cost estimating relationships (CERs). LCAM is capable of interfacing with the Integrated Program Model to provide the cost estimating capability for that suite of tools.

Prince, Andy↗

Influence of Combined Whole-Body Vibration Plus G-Loading on Visual Performance

Recent engineering analyses of the integrated Ares-Orion stack show that vibration levels for Orion crews have the potential to be much higher than those experienced in Gemini, Apollo, and Shuttle vehicles. Of particular concern to the Constellation Program (CxP) is the 12 Hz thrust oscillation (TO) that the Ares-I rocket develops during the final ~20 seconds preceding first-stage separation, at maximum G-loading. While the structural-dynamic mitigations being considered can assure that vibration due to TO is reduced to below the CxP crew health limit, it remains to be determined how far below this limit vibration must be reduced to enable effective crew performance during launch. Moreover, this "performance" vibration limit will inform the operations concepts (and crew-system interface designs) for this critical phase of flight. While Gemini and Apollo studies provide preliminary guidance, the data supporting the historical limits were obtained using less advanced interface technologies and very different operations concepts. In this study, supported by the Exploration Systems Mission Directorate (ESMD) Human Research Program, we investigated display readability-a fundamental prerequisite for any interaction with electronic crew-vehicle interfaces-while observers were subjected to 12 Hz vibration superimposed on the 3.8 G loading expected for the TO period of ascent. Two age-matched groups of participants (16 general population and 13 Crew Office) performed a numerical display reading task while undergoing sustained 3.8 G loading and whole-body vibration at 0, 0.15, 0.3, 0.5, and 0.7 g in the eyeballs in/out (x-axis) direction. The time-constrained reading task used an Orion-like display with 10- and 14-pt non-proportional sans-serif fonts, and was designed to emulate the visual acquisition and processing essential for crew system monitoring. Compared to the no-vibration baseline, we found no significant effect of vibration at 0.15 and 0.3 g on task error rates (ER) or response times (RT). Significant degradations in both ER and RT, however, were observed at 0.5 and 0.7 g for 10-pt, and at 0.7 g for 14-pt font displays. These objective performance measures were mirrored by participants' subjective ratings. Interestingly, we found that the impact of vibration on ER increased with distance from the center of the display, but only for vertical displacements. Furthermore, no significant ER or RT aftereffects were detected immediately following vibration, regardless of amplitude. Lastly, given that our reading task required no specialized spaceflight expertise, our finding that effects were not statistically distinct between our two groups is not surprising. The results from this empirical study provide initial guidance for evaluating the display readability trade-space between text-font size and vibration amplitude. However, the outcome of this work should be considered preliminary in nature for a number of reasons: 1. The single 12 Hz x-axis vibration employed was based on earlier load-cycle models of the induced TO environment at the end of Ares-I first stage flight. Recent analyses of TO mitigation designs suggest that significant concurrent off-axis vibration may also occur. 2. The shirtsleeve environment in which we tested fails to capture the full kinematic and dynamic complexity of the physical interface between crewmember and the still-to-bematured helmet-suit-seat designs, and the impact these will have for vibration transmission and consequent performance. 3. By examining performance in this reading and number processing task, we are only assessing readability, a first and necessary step that in itself does not directly address the performance of more sophisticated operational tasks such as vehicle-health monitoring or manual control of the vehicle.

readability↗

SSME to RS-25: Challenges of Adapting a Heritage Engine to a New Vehicle Architecture

Following the cancellation of the Constellation program and retirement of the Space Shuttle, NASA initiated the Space Launch System (SLS) program to provide next-generation heavy lift cargo and crew access to space. A key constituent of the SLS architecture is the RS-25 engine, also known as the Space Shuttle Main Engine (SSME). The RS-25 was selected to serve as the main propulsion system for the SLS core stage in conjunction with the solid rocket boosters. This selection was largely based on the maturity and extensive experience gained through 135 missions, 3000+ ground tests, and over a million seconds total accumulated hot-fire time. In addition, there were also over a dozen functional flight assets remaining from the Space Shuttle program that could be leveraged to support the first four flights. However, while the RS-25 is a highly mature system, simply unbolting it from the Space Shuttle boat-tail and installing it on the new SLS vehicle is not a "plug-and-play" operation. In addition to numerous technical integration details involving changes to significant areas such as the environments, interface conditions, technical performance requirements, operational constraints and so on, there were other challenges to be overcome in the area of replacing the obsolete engine control system (ECS). While the magnitude of accomplishing this effort was less than that needed to develop and field a new clean-sheet engine system, the path to the first flight of SLS has not been without unexpected challenges.

Ballard, Richard O.↗

A Basic Comparison of the Space Shuttle Main Engine and the J-2X Engine

With the introduction of the new manned space effort through the Constellation Program, there is an interest to have a basic comparison of the current Space Shuttle Main Engine (SSME) to the J-2X engine used for the second stage of both the Ares I and Ares V rockets. This paper seeks to compare size, weight and thrust capabilities while drawing simple conclusions on differences between the two engines.

Ayer, Adam↗