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This slide presentation reviews selected lessons that were learned during the design, development, assembly and operation of the International Space Station. The critical importance of standards and common interfaces is emphasized to create a common operation environment that can lead to flexibility and adaptability.
Design for a modular display panel is based on a cross-shaped corner connector and wooden lattice bars. The bars are fitted into the arms of the metal connector and a pocket slot holds a modular-size panel.
Design of improved vibration test facility for spacecraft
A method for designing and assembling a high performance catalyst bed gas generator for use in decomposing propellants, particularly hydrogen peroxide propellants, for use in target, space, and on-orbit propulsion systems and low-emission terrestrial power and gas generation. The gas generator utilizes a sectioned catalyst bed system, and incorporates a robust, high temperature mixed metal oxide catalyst. The gas generator requires no special preheat apparatus or special sequencing to meet start-up requirements, enabling a fast overall response time. The high performance catalyst bed gas generator system has consistently demonstrated high decomposition efficiency, extremely low decomposition roughness, and long operating life on multiple test articles.
NASA designed, assembled and installed a temperature diode rake into the SHIIVER test article for use of measuring liquid and gaseous hydrogen temperatures. Several special steps were taken to ensure that fluid temperatures were measured as opposed to structural temperatures. This document outlines design practices and methodologies that have become standard practice at Glenn Research Center to ensure the measurement of fluid temperatures for cryogenic systems research.
The design, development, and testing of a wide mass range residual gas analyzer which will be one component of an integrated real time contamination monitor system are described. The instrument has been developed and tested to the laboratory prototype phase, demonstrating the performance that can be expected from a flight instrument of similar design. The instrument's analyzer is of the quadrupole type and a cold cathode ion source is employed as the ionizer. The associated electronics supply all necessary operating and mass sweep voltages for the ionizer, analyzer and electron multiplier ion detector. The instrument features a very fast linear electrometer with automatic range changing. The full mass range of 2 to 300 amu is automatically and repetitively scanned every sixty seconds and suitable telemetry outputs are provided for intensity and mass identification as well as a digital identification of the electrometer range.
Metabolic heat regenerated Temperature Swing Adsorption (MTSA) technology is being developed for thermal and carbon dioxide (CO2) control for a Portable Life Support System (PLSS), as well as water recycling. The core of the MTSA technology is a sorbent bed that removes CO2 from the PLSS ventilation loop gas via a temperature swing. A Condensing Ice Heat eXchanger (CIHX) is used to warm the sorbent while also removing water from the ventilation loop gas. A Sublimation Heat eXchanger (SHX) is used to cool the sorbent. Research was performed to explore an MTSA designed for both lunar and Martian operations. Previously each the sorbent bed, CIHX, and SHX had been built and tested individually on a scale relevant to PLSS operations, but they had not been done so as an integrated subassembly. Design and analysis of an integrated subassembly was performed based on this prior experience and an updated transient system model. Focus was on optimizing the design for Martian operations, but the design can also be used in lunar operations. An Engineering Development Unit (EDU) of an integrated MTSA subassembly was assembled based on the design. Its fabrication is discussed. Some details on the differences between the as-assembled EDU to the future flight unit are considered.
Metabolic heat regenerated Temperature Swing Adsorption (MTSA) technology is being developed for thermal and carbon dioxide (CO2) control for a Portable Life Support System (PLSS), as well as water recycling. The core of the MTSA technology is a sorbent bed that removes CO2 from the PLSS ventilation loop gas via a temperature swing. A Condensing Icing Heat eXchanger (CIHX) is used to warm the sorbent while also removing water from the ventilation loop gas. A Sublimation Heat eXchanger (SHX) is used to cool the sorbent. Research was performed to explore an MTSA designed for both lunar and Martian operations. Previously the sorbent bed, CIHX, and SHX had been built and tested individually on a scale relevant to PLSS operations, but they had not been done so as an integrated subassembly. Design and analysis of an integrated subassembly was performed based on this prior experience and an updated transient system model. Focus was on optimizing the design for Martian operations, but the design can also be used in lunar operations. An Engineering Development Unit (EDU) of an integrated MTSA subassembly was assembled based on the design. Its fabrication is discussed. Some details on the differences between the as-assembled EDU and the future flight unit are considered.
Solar cell submodules with bus bars that leave tabs along one end of the submodule and wires with raised portions along the other end are assembled by interlocking the tabs and wires of adjacent submodules. This structural design is lightweight and reliable and requires no metallic substructure.
Individual redox flow cells are arranged electrically in series and hydraulically in parallel to form a single assembly called a stack. The hardware currently being tested in the laboratory has an active electrode area of either 310 sq cm or 929 sq cm. Four 310 sq cm stacks, each consisting of 39 active cells, were incorporated into a 1.0 kW preprototype system. The physical design of the stack is very critical to the performance and efficiency of the redox storage sytem. This report will discuss the mechanical aspects of the cell and stack design for the current Redox hardware, with regard to sealing the stack internally as well as externally, minimizing shunt currents and minimizing the electrical resistance of the stack.
The development of a cryogenic fluid system to supply liquid hydrogen to a turbopump at flowrates up to 7.5 pounds per second for a period of approximately 5 seconds before refill, is discussed. Refill is accomplished in less than 10 seconds, during which a constant flowrate can be maintained to the pumps. Diagrams are provided to show the configuration of the system. Subsystem acceptance and functional tests, including acquisition subsystem expulsion, pressurization, and refill were performed. The tests included: (1) thermodynamic vent system operation, (2) warm-gas pressurization effects, (3) hydraulic pressure surge effects, (4) screen device operational limitations, (5) feedline vapor control, and (6) two-phase refill.
This slide presentation reviews some of the lessons learned in the sphere of international cooperation during the development, assembly and operation of the International Space Station. From the begining all Partners shared a common objective to build, operate and utilize a crewed laboratory in low orbit as an international partnership. The importance of standards is emphasized.
Flight and ground system operability has been a focus area on the Europa Clipper Project since early in its formulation phase. This has given the operations team the opportunity to influence the design, with a goal of increasing overall system operability. This paper presents example operability challenges, opportunities, and solutions arising from the pre-Critical Design Review (CDR) system design. The integrated wing assembly design directly couples a scientific instrument (the REASON sounding radar) to the spacecraft’s power source (solar array wing panels). Impacts to mission operations of this design include: increased slew durations; solar array pointing constraints during inner cruise, Europa flybys, and orbit trim maneuvers; and stray light intrusions into the stellar reference units’ keep out zones. The use of CCSDS File Delivery Protocol (CFDP) Class-2 for reliable downlink of the large volume of Europa Clipper science data is described, along with nominal and off-nominal use cases. The effort to improve post-launch spacecraft visibility by adding a third low-gain antenna to the spacecraft is detailed. The design of the bulk data store has necessitated the implementation of accountable data products (ADPs), accountability identifiers (AIDs), and metadata packets to provide end-to-end science data accountability. To streamline and automate the flight rules generation and checking process, a first order and temporal logic-based solution of expressing flight rules without ambiguity, and whose programmatic implementation can be automated, is proposed. The focus on operability has had a positive influence on Europa Clipper design decisions, although cost, schedule, budget, heritage, and other technical concerns have many times outweighed operability concerns. However, experience to date demonstrates that this approach to operability results in more thorough, balanced consideration of the effect of early design trades and decisions on the operations phase of a mission than seen in many previous missions, and provides operations development insight into prioritizing work to go.
Flight and ground system operability has been a focus area on the Europa Clipper Project since early in its formulation phase. This has given the operations team the opportunity to influence the design, with a goal of increasing overall system operability. This paper presents example operability challenges, opportunities, and solutions arising from the Critical Design Review (CDR) system design. The integrated wing assembly design directly couples a scientific instrument (the REASON sounding radar) to the spacecraft’s power source (solar array wing panels). Impacts to mission operations of this design include: increased slew durations; solar array pointing constraints during inner cruise, Europa flybys, and orbit trim maneuvers; and stray light intrusions into the stellar reference units’ keep out zones. The use of CCSDS File Delivery Protocol (CFDP) Class-2 for reliable downlink of the large volume of Europa Clipper science data is described, along with nominal and off-nominal use cases. The effort to improve post-launch spacecraft visibility by adding a third low-gain antenna to the spacecraft is detailed. The design of the bulk data store has necessitated the implementation of accountable data products (ADPs), accountability identifiers (AIDs), and metadata packets to provide end-to-end science data accountability. To streamline and automate the flight rules generation and checking process, a first order and temporal logic-based solution of expressing flight rules without ambiguity, and whose programmatic implementation can be automated, is proposed. The focus on operability has had a positive influence on Europa Clipper design decisions, although cost, schedule, budget, heritage, and other technical concerns have many times outweighed operability concerns. However, experience to date demonstrates that this approach to operability results in more thorough, balanced consideration of the effect of early design trades and decisions on the operations phase of a mission than seen in many previous missions, and provides operations development insight into prioritizing work to go.
My tour in the Engineering Robotics directorate exceeded my expectations. I learned lessons about Creo, manufacturing and assembly, collaboration, and troubleshooting. During my first tour, last spring, I used Creo on a smaller project, but had limited experience with it before starting in the Dynamic Systems Test branch this spring. I gained valuable experience learning assembly design, sheet metal design and designing with intent for manufacturing and assembly. These skills came from working both on the hatch and the floor. I also learned to understand the intent of other designers on models I worked with. While redesigning the floor, I was modifying an existing part and worked to understand what the previous designer had done to make it fit with the new model. Through working with the machine shop and in the mock-up, I learned much more about manufacturing and assembly. I used a Dremel, rivet gun, belt sander, and countersink for the first time. Through taking multiple safety training for different machine shops, I learned new machine shop safety skills specific to each one. This semester also gave me new collaborative opportunities. I collaborated with engineers within my branch as well as with Human Factors and the building 10 machine shop. This experience helped me learn how to design for functionality and assembly, not only for what would be easiest in my designs. In addition to these experiences, I learned many lessons in troubleshooting. I was the first person in my office to use a Windows 10 computer. This caused unexpected issues with NASA services and programs, such as the Digital Data Management Server (DDMS). Because of this, I gained experience finding solutions to lockout and freeze issues as well as Creo specific settings. These will be useful skills to have in the future and will be implemented in future rotations. This co-op tour has motivated me more to finish my degree and pursue my academic goals. I intend to take a machining Career Gateway Elective in the Fall to improve my skills in building as well as designing with manufacturing intent. I am also inspired to take more mechatronics CGE courses before I graduate to learn more about the crossover between mechanical and electrical engineering. This semester, I worked on multiple projects and had the opportunity to learn from engineers of different disciplines. I became proficient in Creo 2.0, a program I had not used significantly before. I finished modifying the hatch for 3D print and made sizeable modifications to the nose floor support design. I also gained hands-on experience that will be useful in my engineering career in the future. I would consider all of these major achievements from this spring semester. Lastly, I learned to ask more questions and to search for the right people to find answers which I know will be a valuable skill in the future. This summer, I will be completing my last rotation in the Flight Operations Directorate at Ellington Air Field. After this last tour, I will be returning to school for the Fall, Spring and Summer. I will graduate in August of 2018. I am looking forward to learning more about the different jobs available to engineers. This division works directly with many different types of aircrafts and I am excited to learn more about this focus of engineering. The Aircraft Operations Division values team work greatly and I intend to improve my interpersonal skills by working with them this summer.
Bottom terminated components and quad flat no-lead (BTC/QFN) packages have been extensively used by commercial industry for more than a decade. Cost and performance advantages and the closeness of the packages to the boards make them especially unique for radio frequency (RF) applications. A number of high-reliability parts are now available in this style of package configuration. This report presents a summary of literature surveyed and provides a body of knowledge (BOK) gathered on the status of BTC/QFN and their advanced versions of multi-row QFN (MRQFN) packaging technologies. The report provides a comprehensive review of packaging trends and specifications on design, assembly, and reliability. Emphasis is placed on assembly reliability and associated key design and process parameters because they show lower life than standard leaded package assembly under thermal cycling exposures. Inspection of hidden solder joints for assuring quality is challenging and is similar to ball grid arrays (BGAs). Understanding the key BTC/QFN technology trends, applications, processing parameters, workmanship defects, and reliability behavior is important when judicially selecting and narrowing the follow-on packages for evaluation and testing, as well as for the low risk insertion in high-reliability applications.
Bottom terminated components and quad flat no-lead (BTC/QFN) packages have been extensively used by commercial industry for more than a decade. Cost and performance advantages and the closeness of the packages to the boards make them especially unique for radio frequency (RF) applications. A number of high-reliability parts are now available in this style of package configuration. This report presents a summary of literature surveyed and provides a body of knowledge (BOK) gathered on the status of BTC/QFN and their advanced versions of multi-row QFN (MRQFN) packaging technologies. The report provides a comprehensive review of packaging trends and specifications on design, assembly, and reliability. Emphasis is placed on assembly reliability and associated key design and process parameters because they show lower life than standard leaded package assembly under thermal cycling exposures. Inspection of hidden solder joints for assuring quality is challenging and is similar to ball grid arrays (BGAs). Understanding the key BTC/QFN technology trends, applications, processing parameters, workmanship defects, and reliability behavior is important when judicially selecting and narrowing the follow-on packages for evaluation and testing, as well as for the low risk insertion in high-reliability applications.