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NASA NTRS2009

Design Evolution and Verification of the A-3 Chemical Steam Generator

Following is an overview of the Chemical Steam Generator system selected to provide vacuum conditions for a new altitude test facility, the A-3 Test Stand at Stennis Space Center (SSC) in Bay St. Louis, MS. A-3 will serve as NASA s primary facility for altitude testing of the J-2X rocket engine, to be used as the primary propulsion device for the upper stages of the Ares launch vehicles. The Chemical Steam Generators (CSGs) will produce vacuum conditions in the test cell through the production and subsequent supersonic ejection of steam into a diffuser downstream of the J-2X engine nozzle exit. The Chemical Steam Generators chosen have a rich heritage of operation at rocket engine altitude test facilities since the days of the Apollo program and are still in use at NASA White Sands Test Facility (WSTF) in New Mexico. The generators at WSTF have been modified to a degree, but are still very close to the heritage design. The intent for the A-3 implementation is to maintain this heritage design as much as possible, making minimal updates only where necessary to substitute for obsolete parts and to increase reliability. Reliability improvements are especially desired because the proposed system will require 27 generators, which is nine times the largest system installed in the 1960s. Improvements were suggested by the original design firm, Reaction Motors, by NASA SSC and NASA WSTF engineers, and by the A-3 test stand design contractor, Jacobs Technology, Inc. (JTI). This paper describes the range of improvements made to the design to date, starting with the heritage generator and the minor modifications made over time at WSTF, to the modernized configuration which will be used at A-3. The paper will discuss NASA s investment in modifications to SSC s E-2 test facility fire a full-scale Chemical Steam Generator in advance of the larger steam system installation at A-3. Risk mitigation testing will be performed in early 2009 at this test facility to verify that the CSGs operate as expected. The generator which will undergo this testing is of the most recent A-3 configuration, and will be instrumented far in excess of what is normally required for operation. The extra data will allow for easier troubleshooting and more complete knowledge of expected generator performance. In addition, the early testing will give SSC personnel experience in operating the CSG systems, which will expedite the process of installation and activation at A-3. Each Chemical Steam Generator is supported by a complement of valves, instruments, and flow control devices, with the entire assembly called a "module." The generators will be installed in groups of three, historically called "units". A module is so called because of its modular ability to be replaced or serviced without disturbing the other two modules installed on the same unit. A module is pictured in Figure 1, shown with its generator secured by white bands in its shipping (vs. installed) configuration. The heritage system at WSTF is composed of a single unit (three generator modules), pictured in Figure 2 as it was installed in 1965. In contrast, A-3 will have nine units operating in parallel to achieve vacuum conditions appropriate for testing the J-2X engine. Each of the combustors operates in two modes and achieves the so-called "full-steam" mode after all three of its stages ignite. Ignition of the first stage is achieved by exciting a spark plug; the second stage and main stage are lit by the flame front of the previous stage. The main stage burns approximately 97% of the total propellant flow and uses the heat energy to vaporize water into superheated steam. While the main stage remains unlit, the combustor is in so-called "idle" mode. In the WSTF system, this idle mode is not optimized for water usage, and does not need to be, as the water is pumped from a large reservoir. The water supply at A-3 will be contained in tanks with finite volume, so water optimization is preferred for the modnized configuration. Multiple solutions for this issue have been proposed, with the leading concept being a change to the operational definition of "idle mode," with the generator running in a lower heat flux condition.

Kirchner, Casey K.↗

NASA NTRS1964

Unmanned Spacecraft of the United States

In 1957 the first earth satellite ushered in the age of space flight. Since that historic event, space exploration has become a major national objective of both the United States and the Soviet Union. These two nations have attempted a total of well over 200 space flight missions. Other nations are also participating in various degrees in what will continue to grow as a cooperative world effort. In the years since 1957, man has successfully flown in earth orbit. He has initiated programs to land on the moon and return. He has made dramatic applications of earth satellites in meteorology, communications, navigation, and geodesy. A host of scientific satellites.continue to advance understanding of the earth's environment, the sun, and the stars. Automated spacecraft are being flown to the moon, deep into interplanetary space, and to the near planets, Mars and Venus. One of the most exciting technological aspects of space exploration has been the development of automated spacecraft. Most of the scientific exploration of space and the useful applications of space flight thus far have been made possible by automated spacecraft. Development of these spacecraft and their many complex subsystems is setting the pace today for many branches of science and technology. Guidance, computer, attitude control, power, telecommunication, instrumentation, and structural subsystems are being subjected to new standards of light weight, high efficiency, extreme accuracy, and unsurpassed reliability and quality. This publication reviews the automated spacecraft which have been developed and flown, or which are under active development in the United States by the National Aeronautics and Space Administration. From the facts and statistics contained herein, certain observations can be made and certain conclusions drawn.

Cortright, Edgar M.↗

NASA NTRS2009

UAVSAR - A New Airborne L-Band Radar for Repeat Pass Interferometry

NASA/JPL has developed a new airborne Synthetic Aperture Radar (SAR) which has become available for use by the scientific community in January, 2009. Pod mounted, the UAVSAR was designed to be portable among a variety of aircraft, including unmanned aerial systems (UAS). The instrument operates in the L-Band, has a resolution under 2m from a GPS altitude of 12Km and a swath width of approximately 20Km. UAVSAR currently flies on a modified Gulfstream-III aircraft, operated by NASA s Dryden Flight Research Center at Edwards, California. The G-III platform enables repeat-pass interferometric measurements, by using a modified autopilot and precise kinematic differential GPS to repeatedly fly the aircraft within a specified 10m tube. The antenna is electronically steered along track to assure that the antenna beam can be directed independently, regardless of speed and wind direction. The instrument can be controlled remotely, AS AN OPTION, using the Research Environment for Vehicle Embedded Analysis on Linux (REVEAL). This allows simulation of the telepresence environment necessary for flight on UAS. Potential earth science research and applications include surface deformation, volcano studies, ice sheet dynamics, and vegetation structure.

Mace, Thomas H.↗

NASA NTRS2010

Space-Frame Lunar Lander

The space-frame lunar lander was originally intended to (1) land on rough lunar terrain, (2) deform itself to conform to the terrain so as to be able to remain there in a stable position and orientation, and (3) if required, further deform itself to perform various functions. In principle, the space-frame lunar lander could be used in the same way on Earth, as might be required, for example, to place meteorological sensors or a radio-communication relay station on an otherwise inaccessible mountain peak. the space-frame lunar lander would include a truss-like structure consisting mostly of a tetrahedral mesh of nodes connected by variable-length struts, the lengths of which would be altered in coordination to impart the desired overall size and shape to the structure. Thrusters (that is, small rocket engines), propellant tanks, a control system, and instrumentation would be mounted in and on the structure (see figure). Once it had landed and deformed itself to the terrain through coordinated variations in the lengths of the struts, the structure could be further deformed into another space-frame structure

Curtis, Steven A.↗

NASA NTRS2006

Multi-Platform Avionics Simulator

Multi-Platform Avionics Simulator (MPAvSim) is a software library for development of simulations of avionic hardware. MPAvSim facilitates simulation of interactions between flight software and such avionic peripheral equipment as telecommunication devices, thrusters, pyrotechnic devices, motor controllers, and scientific instruments. MPAvSim focuses on the behavior of avionics as seen by flight software, rather than on performing high-fidelity simulations of dynamics. However, MPAvSim is easily integrable with other programs that do perform such simulations. MPAvSim makes it possible to do real-time partial hardware- in-the-loop simulations. An MPAvSim simulation consists of execution chains (see figure) represented by flow graphs of models, defined here as stateless procedures that do some work. During a simulation, MPAvSim walks the execution chain, running each model in turn. Using MPAvSim, flight software can be run against a spacecraft that is all simulation, all hardware, or part hardware and part simulation. With respect to a specific piece of hardware, either the hardware itself or its simulation can be plugged in without affecting the rest of the system. Thus, flight software can be tested before hardware is available, and as items of hardware become available, they can be substituted for their simulations, with minimal disruption.

Clark, Micah↗

NASA NTRS2005

Subsurface Ice Probe

The subsurface ice probe (SIPR) is a proposed apparatus that would bore into ice to depths as great as hundreds of meters by melting the ice and pumping the samples of meltwater to the surface. Originally intended for use in exploration of subsurface ice on Mars and other remote planets, the SIPR could also be used on Earth as an alternative to coring, drilling, and melting apparatuses heretofore used to sample Arctic and Antarctic ice sheets. The SIPR would include an assembly of instrumentation and electronic control equipment at the surface, connected via a tether to a compact assembly of boring, sampling, and sensor equipment in the borehole (see figure). Placing as much equipment as possible at the surface would help to attain primary objectives of minimizing power consumption, sampling with high depth resolution, and unobstructed imaging of the borehole wall. To the degree to which these requirements would be satisfied, the SIPR would offer advantages over the aforementioned ice-probing systems.

Hecht, Michael↗

NASA NTRS2011

Performance of a Kilowatt-Class Stirling Power Conversion System in a Thermodynamically Coupled Configuration

A pair of 1-kWe free-piston Stirling power convertors has been modified into a thermodynamically coupled configuration, and performance map testing has been completed. This is the same configuration planned for the full-scale 12-kWe power conversion unit (PCU) that will be used in the Fission Power System Technology Demonstration Unit (TDU). The 1-kWe convertors were operated over a range of conditions to evaluate the effects of thermodynamic coupling on convertor performance and to identify any possible control challenges. The thermodynamically coupled convertor showed no measureable difference in performance from the baseline data collected when the engines were separate, and no major control issues were encountered during operation. The results of this test are guiding controller development and instrumentation selection for the TDU.

Geng, Steven M.↗

NASA NTRS2003

Analytic Method for Computing Instrument Pointing Jitter

A new method of calculating the root-mean-square (rms) pointing jitter of a scientific instrument (e.g., a camera, radar antenna, or telescope) is introduced based on a state-space concept. In comparison with the prior method of calculating the rms pointing jitter, the present method involves significantly less computation. The rms pointing jitter of an instrument (the square root of the jitter variance shown in the figure) is an important physical quantity which impacts the design of the instrument, its actuators, controls, sensory components, and sensor- output-sampling circuitry. Using the Sirlin, San Martin, and Lucke definition of pointing jitter, the prior method of computing the rms pointing jitter involves a frequency-domain integral of a rational polynomial multiplied by a transcendental weighting function, necessitating the use of numerical-integration techniques. In practice, numerical integration complicates the problem of calculating the rms pointing error. In contrast, the state-space method provides exact analytic expressions that can be evaluated without numerical integration.

Bayard, David↗

NASA NTRS2012

Benefits of Delay Tolerant Networking for Earth Science Missions

To date there has been much discussion about the value of Delay Tolerant Networking (DTN) for space missions. Claims of various benefits, based on paper analysis, are good; however a benefits statement with empirical evidence to support is even better. This paper presents potential and actual advantages of using DTN for Earth science missions based on results from multiple demonstrations, conducted by the Communications, Standards, and Technology Laboratory (CSTL) at NASA Goddard Space Flight Center (GSFC). Demonstrations included two flight demonstrations using the Earth Observing Mission 1 (EO-1) and the Near Earth Network (NEN), a ground based demonstration over satellite links to the Internet Router in Space (IRIS) payload on Intelsat-14, and others using the NASA Tracking Data Relay Satellite System (TDRSS). Real and potential findings include increased flexibility and efficiency in science campaigns, reduced latency in a collaborative science scenario, and improved scientist-instrument communication and control.

Davis, Faith↗

NASA NTRS2012

MPST Software: MoonKommand

This software automatically processes Sally Ride Science (SRS) delivered MoonKAM camera control files (ccf) into uplink products for the GRAIL-A and GRAIL-B spacecraft as part of an education and public outreach (EPO) extension to the Grail Mission. Once properly validated and deemed safe for execution onboard the spacecraft, MoonKommand generates the command products via the Automated Sequence Processor (ASP) and generates uplink (.scmf) files for radiation to the Grail-A and/or Grail-B spacecraft. Any errors detected along the way are reported back to SRS via email. With Moon Kommand, SRS can control their EPO instrument as part of a fully automated process. Inputs are received from SRS as either image capture files (.ccficd) for new image requests, or downlink/delete files (.ccfdl) for requesting image downlink from the instrument and on-board memory management. The Moon - Kommand outputs are command and file-load (.scmf) files that will be uplinked by the Deep Space Network (DSN). Without MoonKommand software, uplink product generation for the MoonKAM instrument would be a manual process. The software is specific to the Moon - KAM instrument on the GRAIL mission. At the time of this writing, the GRAIL mission was making final preparations to begin the science phase, which was scheduled to continue until June 2012.

Kwok, John H.↗

NASA NTRS2013

NASA Tech Briefs, August 2013

Topics covered include: Radial Internal Material Handling System (RIMS) for Circular Habitat Volumes; Conical Seat Shut-Off Valve; Impact-Actuated Digging Tool for Lunar Excavation; Flexible Mechanical Conveyors for Regolith Extraction and Transport; Remote Memory Access Protocol Target Node Intellectual Property; Soft Decision Analyzer; Distributed Prognostics and Health Management with a Wireless Network Architecture; Minimal Power Latch for Single-Slope ADCs; Bismuth Passivation Technique for High-Resolution X-Ray Detectors; High-Strength, Super-elastic Compounds; Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications; Microgravity Storage Vessels and Conveying-Line Feeders for Cohesive Regolith; CRUQS: A Miniature Fine Sun Sensor for Nanosatellites; On-Chip Microfluidic Components for In Situ Analysis, Separation, and Detection of Amino Acids; Spectroscopic Determination of Trace Contaminants in High-Purity Oxygen; Method of Separating Oxygen From Spacecraft Cabin Air to Enable Extravehicular Activities; Atomic Force Microscope Mediated Chromatography; Sample Analysis at Mars Instrument Simulator; Access Control of Web- and Java-Based Applications; Tool for Automated Retrieval of Generic Event Tracks (TARGET); Bilayer Protograph Codes for Half-Duplex Relay Channels; Influence of Computational Drop Representation in LES of a Droplet-Laden Mixing Layer.

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NASA NTRS2013

Nuclear Thermal Rocket Element Environmental Simulator (NTREES) Upgrade Activities

A key technology element in Nuclear Thermal Propulsion is the development of fuel materials and components which can withstand extremely high temperatures while being exposed to flowing hydrogen. NTREES provides a cost effective method for rapidly screening of candidate fuel components with regard to their viability for use in NTR systems. The NTREES is designed to mimic the conditions (minus the radiation) to which nuclear rocket fuel elements and other components would be subjected to during reactor operation. The NTREES consists of a water cooled ASME code stamped pressure vessel and its associated control hardware and instrumentation coupled with inductive heaters to simulate the heat provided by the fission process. The NTREES has been designed to safely allow hydrogen gas to be injected into internal flow passages of an inductively heated test article mounted in the chamber.

Emrich, William↗

NASA NTRS2017

Marshall Space Flight Center Faculty Fellowship Program

The research projects conducted by the 2016 Faculty Fellows at NASA Marshall Space Flight Center included propulsion studies on propellant issues, and materials investigations involving plasma effects and friction stir welding. Spacecraft Systems research was conducted on wireless systems and 3D printing of avionics. Vehicle Systems studies were performed on controllers and spacecraft instruments. The Science and Technology group investigated additive construction applied to Mars and Lunar regolith, medical uses of 3D printing, and unique instrumentation, while the Test Laboratory measured pressure vessel leakage and crack growth rates.

Six, N. F.↗

NASA NTRSDate not supplied

Developmental and Cryogenic Thermal Vacuum (TVAC) Testing Lessons Learned

Developmental thermal vacuum (TVAC) testing is a critical step in maturing hardware designs and validating performance prior to flight qualification. Unlike qualification or acceptance testing, developmental testing provides flexibility to explore design margins, uncover integration challenges, and refine test approaches before formal verification activities begin. This presentation highlights the value of developmental testing while sharing common pitfalls encountered during developmental TVAC campaigns. Lessons learned from hands-on testing experience, including extensive developmental testing at cryogenic temperatures, will be shared in this presentation. Topics include test planning and preparation, instrumentation strategies, contamination control considerations, troubleshooting unexpected anomalies, and approaches for staying on schedule while meeting test objectives. The audience will gain practical insights and best practices that can improve test efficiency, reduce risk, and enhance the overall success of future developmental TVAC efforts.

Mackenzie Byrnes↗

NASA NTRS1992

LV software for supersonic flow analysis

The NASA Lewis Research Center (LeRC) maintains a leadership position in research into advanced aerospace propulsion systems. For the next generation of aircraft, engine designs continue to involve complex, high-speed flows. Performing the detailed flow diagnostics to properly evaluate these designs requires advanced instrumentation to probe these highly turbulent flows. The hostile flow environment often requires nonintrusive measurement techniques such as the laser velocimeter (LV). Since the LV is a proven instrument for nonintrusive flow measurement, it can provide quantitative velocity data with minimal interference to the flow. Based on anticipated flow conditions, laser velocimeter systems were procured from TSI, Inc. The initial system utilized counter processor technology, but later procurements this past year include a more advanced, correlator-based processor, which significantly improves the overall LV performance. To meet the needs of advanced research into propulsion, this instrument must be integrated into an existing VAX/VMS computer system for data acquisition, processing, and presentation. The work done under this grant before this period concentrated on developing the software required to setup and acquire data from the TSI MI-990 multichannel interface, and the RMR 1989 rotating machinery resolver. With the basis established for controlling the operation of the LV system, software development this past year shifted in emphasis from instrumentation control and data acquisition to data analysis and presentation. The progress of the program is reported.

Bell, William A.↗

NASA NTRS1983

Silicon Sheet Quality is Improved By Meniscus Control

Better quality silicon crystals for solar cells are possible with instrument that monitors position of meniscus as sheet of solid silicon is drawn from melt. Using information on meniscus height, instrument generates feedback signal to control melt temperature. Automatic control ensures more uniform silicon sheets.

Yates, D. A.↗

NASA NTRS1988

An expert system for satellite and instrument data anomaly and fault isolation

A prototype Generic Payload Operations Control System (GPOCC) is being developed at the NASA Jet Propulsion Laboratory to provide a low-cost command and control processing center for science instruments and small payloads. The GPOCC supports the difficult transition from integration and test to flight operations. The prototype will incorporate four expert systems to perform telemetry, command, and mission planning functions as well as telecommunications scheduling. The first of these expert systems to be developed will perform telemetry data analysis and fault isolation, as well as propose corrective action. This Data Analysis Module (DAM) will monitor telemetry data and perform continual data monitoring and trend analysis based on a knowledge base and historic data archived on an optical disk storage device. The system maintains a continuous knowledge database of past system performance characteristics. The goal of the Data Analysis Module is to achieve consistent, dependable and validatable performance, to demonstrate thorough, reliable and fast reasoning, and to reduce the concentration demanded of flight analysis personnel.

Busse, Carl↗

NASA NTRS2008

Apparatus for Sampling Surface Contamination

An apparatus denoted a swab device has been developed as a convenient means of acquiring samples of contaminants from surfaces and suspending the samples in liquids. (Thereafter, the liquids can be dispensed, in controlled volumes, into scientific instruments for analysis of the contaminants.) The swab device is designed so as not to introduce additional contamination and to facilitate, simplify, and systematize the dispensing of controlled volumes of liquid into analytical instruments. The swab device is a single apparatus into which are combined all the equipment and materials needed for sampling surface contamination. The swab device contains disposable components stacked together on a nondisposable dispensing head. One of the disposable components is a supply cartridge holding a sufficient volume of liquid for one complete set of samples. (The liquid could be clean water or another suitable solvent, depending on the application.) This supply of liquid is sealed by Luer valves. At the beginning of a sampling process, the user tears open a sealed bag containing the supply cartridge. A tip on the nondisposable dispensing head is engaged with a Luer valve on one end of the supply cartridge and rotated, locking the supply cartridge on the dispensing head and opening the valve. The swab tip includes a fabric swab that is wiped across the surface of interest to acquire a sample. A sealed bag containing a disposable dispensing tip is then opened, and the swab tip is pushed into the dispensing tip until seated. The dispensing head contains a piston that passes through a spring-loaded lip seal. The air volume displaced by this piston forces the liquid out of the supply cartridge, over the swab, and into the dispensing tip. The piston is manually cycled to enforce oscillation of the air volume and thereby to cause water to flow to wash contaminants from the swab and cause the resulting liquid suspension of contaminants to flow into the dispensing tip. After several cycles to ensure adequate mixing, liquid containing the suspended contaminant sample is dispensed. The disposable components are then removed from the dispensing head, which may then be reused with a fresh set of disposable components.

Wells, Mark↗