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NASA NTRSDate not supplied

Integrated ECLSS Ground Testbed Development and Status for 2025

The reliability of Spacecraft Life Support systems and the associated mass needed to support human spaceflight is one of the largest risks for missions beyond Low Earth Orbit. The reliability of these systems directly corresponds to the number of spares needed to support the mission. Performance improvements for these systems can reduce the consumables needed for long-duration missions. The only integrated spacecraft regenerative Life Support System exists in Low Earth Orbit. It is not practical to use the ISS system to fully understand the reliability of the technology as these systems are currently maintaining a livable environment and crew’s lives are dependent on the availability of these systems. To achieve advancement on reliability and mass, NASA has initiated the development of an Integrated ECLSS ground Testbed. This paper will provide a status on the testbed development, hardware development and areas for investigation. This paper will also cover planned testbed integration and support for Earth Independent Operations (EIO). This paper will be relevant to sessions: 205, 300, 301, 404, 406, 500, 50, 506, and 511.

Christopher Brown↗

NASA NTRS2014

Investigation of HZETRN 2010 as a Tool for Single Event Effect Qualification of Avionics Systems

NASA's future missions are focused on long-duration deep space missions for human exploration which offers no options for a quick emergency return to Earth. The combination of long mission duration with no quick emergency return option leads to unprecedented spacecraft system safety and reliability requirements. It is important that spacecraft avionics systems for human deep space missions are not susceptible to Single Event Effect (SEE) failures caused by space radiation (primarily the continuous galactic cosmic ray background and the occasional solar particle event) interactions with electronic components and systems. SEE effects are typically managed during the design, development, and test (DD&T) phase of spacecraft development by using heritage hardware (if possible) and through extensive component level testing, followed by system level failure analysis tasks that are both time consuming and costly. The ultimate product of the SEE DD&T program is a prediction of spacecraft avionics reliability in the flight environment produced using various nuclear reaction and transport codes in combination with the component and subsystem level radiation test data. Previous work by Koontz, et al.1 utilized FLUKA, a Monte Carlo nuclear reaction and transport code, to calculate SEE and single event upset (SEU) rates. This code was then validated against in-flight data for a variety of spacecraft and space flight environments. However, FLUKA has a long run-time (on the order of days). CREME962, an easy to use deterministic code offering short run times, was also compared with FLUKA predictions and in-flight data. CREME96, though fast and easy to use, has not been updated in several years and underestimates secondary particle shower effects in spacecraft structural shielding mass. Thus, this paper will investigate the use of HZETRN 20103, a fast and easy to use deterministic transport code, similar to CREME96, that was developed at NASA Langley Research Center primarily for flight crew ionizing radiation dose assessments. HZETRN 2010 includes updates to address secondary particle shower effects more accurately, and might be used as another tool to verify spacecraft avionics system reliability in space flight SEE environments.

Rojdev, Kristina↗

NASA NTRS2008

Cell-Detection Technique for Automated Patch Clamping

A unique and customizable machinevision and image-data-processing technique has been developed for use in automated identification of cells that are optimal for patch clamping. [Patch clamping (in which patch electrodes are pressed against cell membranes) is an electrophysiological technique widely applied for the study of ion channels, and of membrane proteins that regulate the flow of ions across the membranes. Patch clamping is used in many biological research fields such as neurobiology, pharmacology, and molecular biology.] While there exist several hardware techniques for automated patch clamping of cells, very few of those techniques incorporate machine vision for locating cells that are ideal subjects for patch clamping. In contrast, the present technique is embodied in a machine-vision algorithm that, in practical application, enables the user to identify good and bad cells for patch clamping in an image captured by a charge-coupled-device (CCD) camera attached to a microscope, within a processing time of one second. Hence, the present technique can save time, thereby increasing efficiency and reducing cost. The present technique involves the utilization of cell-feature metrics to accurately make decisions on the degree to which individual cells are "good" or "bad" candidates for patch clamping. These metrics include position coordinates (x,y) in the image plane, major-axis length, minor-axis length, area, elongation, roundness, smoothness, angle of orientation, and degree of inclusion in the field of view. The present technique does not require any special hardware beyond commercially available, off-the-shelf patch-clamping hardware: A standard patchclamping microscope system with an attached CCD camera, a personal computer with an imagedata- processing board, and some experience in utilizing imagedata- processing software are all that are needed. A cell image is first captured by the microscope CCD camera and image-data-processing board, then the image data are analyzed by software that implements the present machine-vision technique. This analysis results in the identification of cells that are "good" candidates for patch clamping (see figure). Once a "good" cell is identified, a patch clamp can be effected by an automated patchclamping apparatus or by a human operator. This technique has been shown to enable reliable identification of "good" and "bad" candidate cells for patch clamping. The ultimate goal in further development of this technique is to combine artificial-intelligence processing with instrumentation and controls in order to produce a complete "turnkey" automated patch-clamping system capable of accurately and reliably patch clamping cells with a minimum intervention by a human operator. Moreover, this technique can be adapted to virtually any cellular-analysis procedure that includes repetitive operation of microscope hardware by a human.

McDowell, Mark↗

NASA NTRSDate not supplied

Verification and Validation of Elastodynamic Simulation Software for Aerospace Research

Physics-based simulation of nondestructive evaluation (NDE) inspection can help to advance the inspectability and reliability of mechanical systems. However, NDE simulations applicable to non-idealized mechanical components often require large compute domains and long run times. This has prompted development of custom NDE simulation software tailored to high performance computing (HPC) hardware. Verification and validation (V&V) is an integral part of developing this software to ensure implementations are robust and applicable to inspection problems, producing tools and simulations suitable for computational NDE research. This presentation addresses factors common to V&V of several elastodynamic simulation codes applicable to ultrasonic NDE. Examples are drawn from in-house simulation software at NASA Langley Research Center, ranging from ensuring reliability in a 1D heterogeneous media wave equation solver to the V&V needs of 3D cluster-parallel elastodynamic software. Factors specific to a research environment are addressed, where individual simulation results can be as relevant as the software product itself. Distinct facets of V&V are discussed including testing to establish software reliability, employing systematic approaches for consistency with fundamental conservation laws, establishing the numerical stability of algorithms, and demonstrating concurrence with empirical data. This talk also addresses V&V practices for small groups of researchers. This includes establishing resources (e.g. time and personnel) for V&V during project planning to mitigate and control the risk of setbacks. Similarly, we identify ways for individual researchers to use V&V during simulation software development itself to both speed up the development process and reduce incurred technical debt.

NDE↗

NASA NTRS2011

Solid Rocket Booster (SRB) - Evolution and Lessons Learned During the Shuttle Program

The Solid Rocket Booster (SRB) element integrates all the subsystems needed for ascent flight, entry, and recovery of the combined Booster and Motor system. These include the structures, avionics, thrust vector control, pyrotechnic, range safety, deceleration, thermal protection, and retrieval systems. This represents the only human-rated, recoverable and refurbishable solid rocket ever developed and flown. Challenges included subsystem integration, thermal environments and severe loads (including water impact), sometimes resulting in hardware attrition. Several of the subsystems evolved during the program through design changes. These included the thermal protection system, range safety system, parachute/recovery system, and others. Obsolescence issues occasionally required component recertification. Because the system was recovered, the SRB was ideal for data and imagery acquisition, which proved essential for understanding loads and system response. The three main parachutes that lower the SRBs to the ocean are the largest parachutes ever designed, and the SRBs are the largest structures ever to be lowered by parachutes. SRB recovery from the ocean was a unique process and represented a significant operational challenge; requiring personnel, facilities, transportation, and ground support equipment. The SRB element achieved reliability via extensive system testing and checkout, redundancy management, and a thorough postflight assessment process. Assembly and integration of the booster subsystems was a unique process and acceptance testing of reused hardware components was required for each build. Extensive testing was done to assure hardware functionality at each level of stage integration. Because the booster element is recoverable, subsystems were available for inspection and testing postflight, unique to the Shuttle launch vehicle. Problems were noted and corrective actions were implemented as needed. The postflight assessment process was quite detailed and a significant portion of flight operations. The SRBs provided fully redundant critical systems including thrust vector control, mission critical pyrotechnics, avionics, and parachute recovery system. The design intent was to lift off with full redundancy. On occasion, the redundancy management scheme was needed during flight operations. This paper describes some of the design challenges, how the design evolved with time, and key areas where hardware reusability contributed to improved system level understanding.

Kanner, Howard S.↗

DOE OSTI2025

Real-Time Lifetime Prediction of Semiconductor Devices Using Hardware-in-the-Loop

This paper presents a unique approach to enable real-time lifespan prediction of semiconductor power modules using a Hardware-in-the-Loop (HIL) system. By integrating the module's overall loss characteristics-specifically switching and conduction losses-with a thermoelectric model of the thermal management system, this research demonstrates that the model can dynamically estimates the junction temperature profile of the semiconductor devices in response to a changing torque demand profile for the motor drive system. This capability enables continuous monitoring of the module's operational time and cumulative stress induced on the devices to compute accumulated remaining lifetime or time-to-failure (TTF). This study provides an architectural framework for the HIL system with high-fidelity component models of multiple physical domains, allowing simulation of dynamic behaviors of a closely-coupled motor drive system. The advanced real-time computation and measurement functionalities of the HIL system allow for both dynamic lifetime calculations based on simulated data and aggregate lifetime predictions utilizing historical data. Moreover, this paper details an algorithm that not only computes cumulative damage but also synthesizes these data into a comprehensive aggregated lifetime metric. This methodology can enhance the maintenance scheduling strategies and operational reliability of semiconductor devices in critical applications, ultimately extending their service life while optimizing performance.

hardware-in-the-loop (HIL)↗

NASA NTRS1972

Electron/proton spectrometer certification documentation analyses

A compilation of analyses generated during the development of the electron-proton spectrometer for the Skylab program is presented. The data documents the analyses required by the electron-proton spectrometer verification plan. The verification plan was generated to satisfy the ancillary hardware requirements of the Apollo Applications program. The certification of the spectrometer requires that various tests, inspections, and analyses be documented, approved, and accepted by reliability and quality control personnel of the spectrometer development program.

Gleeson, P.↗

NASA NTRS1979

Care 3, Phase 1, volume 1

A computer program to aid in accessing the reliability of fault tolerant avionics systems was developed. A simple mathematical expression was used to evaluate the reliability of any redundant configuration over any interval during which the failure rates and coverage parameters remained unaffected by configuration changes. Provision was made for convolving such expressions in order to evaluate the reliability of a dual mode system. A coverage model was also developed to determine the various relevant coverage coefficients as a function of the available hardware and software fault detector characteristics, and subsequent isolation and recovery delay statistics.

Stiffler, J. J.↗

NASA NTRS1981

MSFC evaluation of the space fabrication demonstration system (beam builder)

The beam builder, designed and manufactured as a ground demonstration model, is a precursor to a machine for use in the space environment, transportable by the space shuttle. The beam builder has the capability to automatically fabricate triangular truss beams in low Earth orbit with a highly reliable machine that requires a minimum of in-space maintenance and repair. A performance assessment of the beam builder, which was fabricated from commercial hardware is given.

Adams, E. O.↗

NASA NTRS1987

Fiber optics for controls

The challenge of those involved in control-system hardware development is to accommodate an ever-increasing complexity in aircraft control, while limiting the size and weight of the components and improving system reliability. A technology that displays promise towards this end is the area of fiber optics for controls. The primary advantages of employing optical fibers, passive optical sensors, and optically controlled actuators are weight and volume reduction, immunity from electromagnetic effects, superior bandwidth capabilities, and freedom from short circuits and sparking contacts. Since 1975, NASA Lewis has performed in-house, contract, and grant research in fiber optic sensors, high-temperature electro-optic switches, and fly-by-light control-system architecture. Passive optical sensor development is an essential yet challenging area of work and has therefore received much attention during this period. A major effort to develop fly-by-light control-system technology, known as the Fiber-Optic Control System Integration (FOCSI) program, was initiated in 1985 as a cooperative effort between NASA and DOD. Phase 1 of FOCSI, completed in 1986, was aimed at the design of a fiber-optic integrated propulsion/flight control system. Phase 2, yet to be initiated, will provide subcomponent and system development, and a system engine test. In addition to a summary of the benefits of fiber optics, the FOCSI program, sensor advances, and future directions in the NASA Lewis program will be discussed.

Seng, Gary T.↗

NASA NTRS1988

Overview of NASA research in fiber optics for aircraft controls

The challenge of those involved in aircraft control system hardware development is to accommodate an ever-increasing complexity in aircraft control, while limiting the size and weight of the components and improving system reliability. A technology that displays promise towards this end is fiber optics. The primary advantages of employing optical fibers, passive optical sensors and optically controlled actuators are weight/volume reduction, immunity from electromagnetic effects, high bandwidth capabilities and freedom from short circuits/sparking contacts. Since 1975, NASA Lewis has been performing in-house, contract and grant research in fiber optic sensors, high temperature electro-optic switches and fly-by-light control system architecture. Passive optical sensor development is an essential yet challenging area of work and has therefore received much attention during this period. A major effort to develop fly-by-light control system technology, known as the Fiber Optic Control System Integration (FOCSI) program, was initiated in 1985 as a cooperative effort between NASA and DOD. Phase 1 of FOCSI, completed in 1986, was aimed at the design of a fiber optic integrated propulsion/flight control system. Phase 2 will provide subcomponent and system development and system testing. In addition to a summary of the benefits of fiber optics, the FOCSI program, sensor advances, and future directions in the NASA Lewis program are discussed.

Seng, Gary T.↗

NASA NTRS1991

Augmentation of the space station module power management and distribution breadboard

The space station module power management and distribution (SSM/PMAD) breadboard models power distribution and management, including scheduling, load prioritization, and a fault detection, identification, and recovery (FDIR) system within a Space Station Freedom habitation or laboratory module. This 120 VDC system is capable of distributing up to 30 kW of power among more than 25 loads. In addition to the power distribution hardware, the system includes computer control through a hierarchy of processes. The lowest level consists of fast, simple (from a computing standpoint) switchgear that is capable of quickly safing the system. At the next level are local load center processors, (LLP's) which execute load scheduling, perform redundant switching, and shed loads which use more than scheduled power. Above the LLP's are three cooperating artificial intelligence (AI) systems which manage load prioritizations, load scheduling, load shedding, and fault recovery and management. Recent upgrades to hardware and modifications to software at both the LLP and AI system levels promise a drastic increase in speed, a significant increase in functionality and reliability, and potential for further examination of advanced automation techniques. The background, SSM/PMAD, interface to the Lewis Research Center test bed, the large autonomous spacecraft electrical power system, and future plans are discussed.

Walls, Bryan↗

NASA NTRS1991

Explosive Transient Camera (ETC) Program

Since the inception of the ETC program, a wide range of new technologies was developed to support this astronomical instrument. The prototype unit was installed at ETC Site 1. The first partially automated observations were made and some major renovations were later added to the ETC hardware. The ETC was outfitted with new thermoelectrically-cooled CCD cameras and a sophisticated vacuum manifold, which, together, made the ETC a much more reliable unit than the prototype. The ETC instrumentation and building were placed under full computer control, allowing the ETC to operate as an automated, autonomous instrument with virtually no human intervention necessary. The first fully-automated operation of the ETC was performed, during which the ETC monitored the error region of the repeating soft gamma-ray burster SGR 1806-21.

Ricker, George↗

NASA NTRS1991

An autonomous rendezvous and docking system using cruise missile technology

In November 1990 General Dynamics demonstrated an AR&D system for members of the Strategic Avionics Technology Working Group. This simulation utilized prototype hardware derived from the Cruise Missile and Centaur avionics systems. The object of this proof of concept demonstration was to show that all the accuracy, reliability, and operational requirements established for a spacecraft to dock with Space Station Freedom could be met by the proposed AR&D system.

Jones, ED↗

NASA NTRS2005

CRYOGENIC UPPER STAGE SYSTEM SAFETY

NASA s Exploration Initiative will require development of many new systems or systems of systems. One specific example is that safe, affordable, and reliable upper stage systems to place cargo and crew in stable low earth orbit are urgently required. In this paper, we examine the failure history of previous upper stages with liquid oxygen (LOX)/liquid hydrogen (LH2) propulsion systems. Launch data from 1964 until midyear 2005 are analyzed and presented. This data analysis covers upper stage systems from the Ariane, Centaur, H-IIA, Saturn, and Atlas in addition to other vehicles. Upper stage propulsion system elements have the highest impact on reliability. This paper discusses failure occurrence in all aspects of the operational phases (Le., initial burn, coast, restarts, and trends in failure rates over time). In an effort to understand the likelihood of future failures in flight, we present timelines of engine system failures relevant to initial flight histories. Some evidence suggests that propulsion system failures as a result of design problems occur shortly after initial development of the propulsion system; whereas failures because of manufacturing or assembly processing errors may occur during any phase of the system builds process, This paper also explores the detectability of historical failures. Observations from this review are used to ascertain the potential for increased upper stage reliability given investments in integrated system health management. Based on a clear understanding of the failure and success history of previous efforts by multiple space hardware development groups, the paper will investigate potential improvements that can be realized through application of system safety principles.

Smith, R. Kenneth↗

NASA NTRS2013

Management of the Atmosphere Resource Recovery and Environmental Monitoring Project

The Advanced Exploration Systems Program's Atmosphere Resource Recovery and Environmental Monitoring (ARREM) project is working to further optimize atmosphere revitalization and environmental monitoring system architectures. This paper discusses project management strategies that tap into skill sets across multiple engineering disciplines, projects, field centers, and industry to achieve the project success. It is the project's objective to contribute to system advances that will enable sustained exploration missions beyond Lower Earth Orbit (LEO) and improve affordability by focusing on the primary goals of achieving high reliability, improving efficiency, and reducing dependence on ground-based logistics resupply. Technology demonstrations are achieved by infusing new technologies and concepts with existing developmental hardware and operating in a controlled environment simulating various crewed habitat scenarios. The ARREM project's strengths include access to a vast array of existing developmental hardware that perform all the vital atmosphere revitalization functions, exceptional test facilities to fully evaluate system performance, and a well-coordinated partnering effort among the NASA field centers and industry partners to provide the innovative expertise necessary to succeed.

Roman, Monsi↗

NASA NTRSDate not supplied

Metrics in Space Life Support Technology Selection

Engineering metrics are useful in space life support technology selection, but they must be carefully used. Metrics are only part of a complete system trade-off. Metrics do harm if they cause neglect of other important technical, organizational, or intuitive decision factors. Two metrics have damaged space life support, closure and Equivalent Systems Mass (ESM). Closure measures the fraction of the required system inputs that are produced by recycling system outputs. Increasing closure produces diminishing returns and becomes increasingly expensive. Increasing closure does not directly contribute to providing better life support. ESM measures the total launch mass required to provide life support. ESM includes the mass of the system hardware and of its power, cooling, pressurized volume, spares, and logistics. ESM predicts launch costs, but recently launch costs have been reduced by a factor of 20 or more. System development cost for space hardware is often much greater than launch cost. The past nearly exclusive use of ESM has led to the neglect of Life Cycle Cost (LCC), reliability, cost, and the other engineering factors. Closure and ESM have misguided space life support technology selection for more than twenty years and have adversely affected the expenditure of 100’s of millions of dollars. Metrics can be effectively used three ways in space life support technology selection: 1. A small set of key engineering metrics for preliminary screening. 2. A full set of engineering to guide technical selection. 3. Combining engineering metrics with organizational, political, and intuitive decision factors to understand technology selection. The past emphasis on closure and ESM served to support recycling life support over resupply and built on the intuitive appeal of a human ecosystem in space.

Harry W Jones↗

NASA NTRSDate not supplied

The Effective Use of Metrics in Space Life Support System Trade-Offs

Harry W. Jones↗