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Integrated Ground Operations Demonstration Units Testing Plans and Status

Cryogenic propellant loading operations with their associated flight and ground systems are some of the most complex, critical activities in launch operations. Consequently, these systems and operations account for a sizeable portion of the life cycle costs of any launch program. NASA operations for handling cryogens in ground support equipment have not changed substantially in 50 years, despite advances in cryogenics, system health management and command and control technologies. This project was developed to mature, integrate and demonstrate advancement in the current state of the art in these areas using two distinct integrated ground operations demonstration units (GODU): GODU Integrated Refrigeration and Storage (IRAS) and GODU Autonomous Control

Johnson, Robert G.

Software unit testing in Ada environment

A validation procedure for the Ada binding of the Graphical Kernel System (GKS) is being developed. PRIOR Data Sciences is also producing a version of the GKS written in Ada. These major software engineering projects will provide an opportunity to demonstrate a sound approach for software testing in an Ada environment. The GKS/Ada validation capability will be a collection of test programs and data, and test management guidelines. These products will be used to assess the correctness, completeness, and efficiency of any GKS/Ada implementation. The GKS/Ada developers will be able to obtain the validation software for their own use. It is anticipated that this validation software will eventually be taken over by an independent standards body to provide objective assessments of GKS/Ada implementations, using an approach similar to the validation testing currently applied to Ada compilers. In the meantime, if requested, this validation software will be used to assess GKS/Ada products. The second project, implementation of GKS using the Ada language, is a conventional software engineering tasks. It represents a large body of Ada code and has some interesting testing problems associated with automatic testing of graphics routines. Here the normal test practices which include automated regression testing, independent quality assistance, test configuration management, and the application of software quality metrics will be employed. The software testing methods emphasize quality enhancement and automated procedures. Ada makes some aspects of testing easier, and introduces some concerns. These issues are addressed.

Warnock, Glenn

Development of the Plant Growth Facility for Use in the Shuttle Middeck and Test Units for Ground-Based Experiments

The plant growth facility (PGF), currently under development as a Space Shuttle middeck facility for the support of research on higher plants in microgravity, is presented. The PGF provides controlled fluorescent lighting and the active control of temperature, relative humidity and CO2 concentration. These parameters are designed to be centrally controlled by a dedicated microprocessor. The status of the experiment can be displayed for onboard analysis, and will be automatically archived for post-flight analysis. The facility is designed to operate for 15 days and will provide air filtration to remove ethylene and trace organics with replaceable potassium permanganate filters. Similar ground units will be available for pre-flight experimentation.

Chapman, David K.

Calibration Plan for the Ocean Color Instrument (OCI) Engineering Test Unit

The basic product measured by OCI is the top-of atmosphere (TOA) radiance at different wavelengthsThree types of calibration/characterization are necessary for ocean color processing: - Prelaunch calibration/characterization (absolute/spectral calibration and image artifacts) - On-orbit calibration (solar diffuser and lunar measurements) - Vicarious calibration (in-situ measurements of water-leaving radiance)

Meister, Gerhard

System Testing of Ground Cooling System Components

This internship focused primarily upon software unit testing of Ground Cooling System (GCS) components, one of the three types of tests (unit, integrated, and COTS/regression) utilized in software verification. Unit tests are used to test the software of necessary components before it is implemented into the hardware. A unit test determines that the control data, usage procedures, and operating procedures of a particular component are tested to determine if the program is fit for use. Three different files are used to make and complete an efficient unit test. These files include the following: Model Test file (.mdl), Simulink SystemTest (.test), and autotest (.m). The Model Test file includes the component that is being tested with the appropriate Discrete Physical Interface (DPI) for testing. The Simulink SystemTest is a program used to test all of the requirements of the component. The autotest tests that the component passes Model Advisor and System Testing, and puts the results into proper files. Once unit testing is completed on the GCS components they can then be implemented into the GCS Schematic and the software of the GCS model as a whole can be tested using integrated testing. Unit testing is a critical part of software verification; it allows for the testing of more basic components before a model of higher fidelity is tested, making the process of testing flow in an orderly manner.

Unit Test

Lessons Learned in Space Life Support System Testing

The earlier problems can be found and corrected, the easier and cheaper it is to fix them. Doing less testing saves cost and time but doing too little testing increases the risk of operational failures causing large costs and delays. Integrated test is necessary to determine if the subsystems work together and the overall architecture performs as intended. This report reviews the testing lessons learned from the NASA Systems Engineering Handbook, a National Research Council report, and five reviews of International Space Station (ISS) lessons learned. The five reviews all mention two important points. First, that testing should be performed on the final integrated system, one as close as possible to the intended flight system. Second, “test as you fly,” while operating as planned in an environment as close as possible to the expected flight environment. Other lessons are the need for extensive preflight ground testing, the need to establish and defend an adequate budget, the problems using protoflight hardware on ISS, and the benefit of having ISS as a zero gravity test bed. The major ISS life support systems, carbon dioxide, water recycling, and oxygen recovery, were protoflight systems with little testing before launch to ISS. The failure rates these systems have been much greater than predicted and this has caused dissatisfaction with the protoflight approach. The more costly traditional approach is building qualification and test units in addition to flight units. The test units are used to test, analyze, and fix failure modes. Other work shows that there is an optimum cost-effective intuitive appeal of a human ecosystem in space.

Life support

Guidelines for testing and release procedures

Guidelines and procedures are recommended for the testing and release of the types of computer software efforts commonly performed at NASA/Ames Research Center. All recommendations are based on the premise that testing and release activities must be specifically selected for the environment, size, and purpose of each individual software project. Guidelines are presented for building a Test Plan and using formal Test Plan and Test Care Inspections on it. Frequent references are made to NASA/Ames Guidelines for Software Inspections. Guidelines are presented for selecting an Overall Test Approach and for each of the four main phases of testing: (1) Unit Testing of Components, (2) Integration Testing of Components, (3) System Integration Testing, and (4) Acceptance Testing. Tools used for testing are listed, including those available from operating systems used at Ames, specialized tools which can be developed, unit test drivers, stub module generators, and the use of format test reporting schemes.

Molari, R.

Lessons Learned in Space Life Support System Testing

The earlier problems can be found and corrected, the easier and cheaper it is to fix them. Doing less testing saves cost and time but doing too little testing increases the risk of operational failures causing large costs and delays. Integrated test is necessary to determine if the subsystems work together and the overall architecture performs as intended. This report reviews the testing lessons learned from the NASA Systems Engineering Handbook, a National Research Council report, and five reviews of International Space Station (ISS) lessons learned. The five reviews all mention two important points. First, that testing should be performed on the final integrated system, one as close as possible to the intended flight system. Second, “test as you fly,” while operating as planned in an environment as close as possible to the expected flight environment. Other lessons are the need for extensive preflight ground testing, the need to establish and defend an adequate budget, the problems using protoflight hardware on ISS, and the benefit of having ISS as a zero gravity test bed. The major ISS life support systems, carbon dioxide removal, water recycling, and oxygen recovery, were protoflight systems with little testing before launch to ISS. The failure rates of these systems have been much greater than predicted and this has caused dissatisfaction with the protoflight approach. The more costly traditional approach builds qualification and test units in addition to flight units. The test units are used to find, analyze, and fix failure modes. Other work shows that there is an optimum cost-effective amount of testing when redundant systems must have a specified reliability and confidence.

Harry W. Jones

DC-10 composite vertical stabilizer ground test program

A review of the structural configuration and ground test program is presented. Particular emphasis is placed on the testing of a full-scale stub box test subcomponent and full span ground test unit. The stub box subcomponent was tested in an environmental chamber under ambient, cold/wet, and hot/wet conditions. The test program included design limit static loads, fatigue spectrum loading to approximately two service lifetimes (with and without damage), design limit damage tolerance tests, and a final residual strength test to a structural failure. The first full-scale ground test unit was tested under ambient conditions. The test unit was to have undergone static, fatigue, and damage tolerance tests but a premature structural failure occurred at design limit load during the third limit load test. A failure theory was developed which explains the similarity in types of failure and the large load discrepancy at failure between the two test articles. The theory attributes both failures to high stress concentrations at the edge of the lower rear spar access opening. A second full-scale ground test unit has been modified to incorporate the various changes resulting from the premature failure. The article has been assembled and is active in the test program.

Palmer, J. M., Jr.

Structural testing of concorde aircraft: Further report on United Kingdom tests

A summary of tests conducted on the Concorde aircraft nacelle structure is presented. The tests were conducted as a part of the structural development and certification program. The nacelle structural specimens are described. The problems associated with the intake testing and engine-bay and nozzle testing are discussed.

Harpur, N.

Acquisition of the QPSK demodulator in the presence of interference

The acquisition behavior of the tracking and data relay satellite system (TDRSS) receiver (a quadrative phase-shift keying (QPSK) demodulator using a dither lock detector) in the presence of interference from another user has been analyzed using a simulation model. The demodulator is composed of an automatic gain control, a QPSK Costas loop, a frequency sweep unit, lock test units, and a control unit. The simulation model has been tested for the following variables: signal and interference Doppler frequencies and phase offsets (with respect to initial voltage control oscillator setup), signal-to-interference ratio (SIR), and signal I/Q power ratio. The simulation results are discussed.

Ghazvinian, Farzad

10 kW solar array switching unit performance test results

Solar array switching unit (SASU) technology is an attractive candidate for output power regulation of solar arrays. It offers greater efficiency, lower parts count, modularity and expandability. Since the SASU has switching frequencies upwards of 15 kHz, it was necessary to determine the performance characteristics of the SASU with a real solar array and to assess the impact of long lead lengths on the switching characteristics. To accommodate these requirements, TRW developed a 10 kW, 120 volt SASU which was tested for steady state and transient resistive and converter type loadings. The results of these tests are presented and discussed in this paper.

Fleck, G. W.