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NASA NTRSDate not supplied

An Improved Weighted Least Squares Algorithm for the Analysis of Strain-Gage Balance Calibration Data

An improved version of an algorithm is presented that uses a weighted least squares fit of balance calibration data for the generation of the balance load prediction equations. The weighted least squares fit assigns a weighting factor between zero and one to each calibration data point that depends on a simple count of the number of intentionally loaded balance gages. The greater the number of the loaded gages is, the smaller a data point's weighting factor becomes. This strategy has two advantages. First, single-component loads become more influential during the regression analysis of the calibration data. In addition, the negative influence of load schedule asymmetries on the regression analysis results can more effectively be controlled. The original algorithm of 2017 was improved in 2020. Now, gage output differences relative to the natural zeros are exclusively used as input for the determination of the number of intentionally loaded gages. The improved weighted least squares fit can be applied with both the Non-Iterative Method and the Iterative Method that are used for the balance load prediction in the aerospace testing community. Machine calibration data of a force balance is used to illustrate benefits of the application of the improved weighted least squares fit of balance calibration data.

strain-gage balance↗
NASA NTRS2003

Flight-Test Evaluation of Flutter-Prediction Methods

The flight-test community routinely spends considerable time and money to determine a range of flight conditions, called a flight envelope, within which an aircraft is safe to fly. The cost of determining a flight envelope could be greatly reduced if there were a method of safely and accurately predicting the speed associated with the onset of an instability called flutter. Several methods have been developed with the goal of predicting flutter speeds to improve the efficiency of flight testing. These methods include (1) data-based methods, in which one relies entirely on information obtained from the flight tests and (2) model-based approaches, in which one relies on a combination of flight data and theoretical models. The data-driven methods include one based on extrapolation of damping trends, one that involves an envelope function, one that involves the Zimmerman-Weissenburger flutter margin, and one that involves a discrete-time auto-regressive model. An example of a model-based approach is that of the flutterometer. These methods have all been shown to be theoretically valid and have been demonstrated on simple test cases; however, until now, they have not been thoroughly evaluated in flight tests. An experimental apparatus called the Aerostructures Test Wing (ATW) was developed to test these prediction methods.

Lind, RIck↗
NASA NTRS2007

NDE Methods for the External Tank Spray on Foam Insulation

The foam thermal protection system (TPS) of the space shuttle External Tank (ET) has provided some unique challenges to the nondestructive testing community. Three nondestructive evaluation methods have been developed to identify defects in the foam TPS of the ET. Terahertz imaging and backscatter radiography have been developed to identify voids in thick foam regions while shearography has been developed to identify shallow delaminations, shallow voids and crush damage in the foam. The basic theory of operation along with factors, determined from a series of designed experiments, affecting the results of these methods will be described. Results from both test panels and flight tank inspections will be provided, along with predicted probability of detection estimates to show the range in defect sizes and types that can be readily detected.

Walker, James L.↗
NASA NTRS2007

X-31 Mishap: Lessons Learned

The experimental X-31 High Angle of Attack Research Aircraft crashed during a 1995 test mission flight conducted by NASA at Edwards Air Force Base, California. The pilot lost control of the airplane and was forced to eject, sustaining a permanent back injury that ended his flying career. Prior to this incident the airplane had a perfect record of several hundred non-eventful flights supported by an experienced team. During the subsequent investigation by a mishap committee it was discovered that a series of cascading events contributed to this accident. Some of the identified contributing factors that resulted in this mishap are common to aircraft design and to flight-test in general. The mistakes and the solutions are presented here so that the flight-test community may consider and learn from them. The primary cause of the crash was icing and, ultimately, a complete blockage of the pitot-static nose probe. The icing was caused by a freak weather phenomenon that was neither expected nor known to exist on the day of the mishap. The normal probe had been replaced with a special Kiel probe to allow total pressure measurements of up to 70 degrees angle of attack for flight-test purposes. The Kiel probe did not include a heater, because it was assumed that the airplane would not be flown in the clouds or in conditions conducive to icing. This assumption was later proven to be incorrect. The iced Kiel probe caused incorrect gain scheduling in the flight control system, resulting in an unstable aircraft. This failure was essentially undetected because of a faulty design in the flight control system architecture. There were, however, also a number of other issues that lead up to this situation that never should have happened. This presentation discusses what the issues were that contributed to the incident. After the incident was investigated, some of these issues were addressed and some changes were made. The second X-31 aircraft flew the remainder of the flight tests, and the program was successfully completed without incident. This presentation also shows a video of the mishap including lessons learned, and the changes that were made to resume the flight-test program are presented.

Larson, Richard R.↗
NASA NTRS2016

Assessment of the Uniqueness of Wind Tunnel Strain-Gage Balance Load Predictions

A new test was developed to assess the uniqueness of wind tunnel strain-gage balance load predictions that are obtained from regression models of calibration data. The test helps balance users to gain confidence in load predictions of non-traditional balance designs. It also makes it possible to better evaluate load predictions of traditional balances that are not used as originally intended. The test works for both the Iterative and Non-Iterative Methods that are used in the aerospace testing community for the prediction of balance loads. It is based on the hypothesis that the total number of independently applied balance load components must always match the total number of independently measured bridge outputs or bridge output combinations. This hypothesis is supported by a control volume analysis of the inputs and outputs of a strain-gage balance. It is concluded from the control volume analysis that the loads and bridge outputs of a balance calibration data set must separately be tested for linear independence because it cannot always be guaranteed that a linearly independent load component set will result in linearly independent bridge output measurements. Simple linear math models for the loads and bridge outputs in combination with the variance inflation factor are used to test for linear independence. A highly unique and reversible mapping between the applied load component set and the measured bridge output set is guaranteed to exist if the maximum variance inflation factor of both sets is less than the literature recommended threshold of five. Data from the calibration of a six{component force balance is used to illustrate the application of the new test to real-world data.

strain-gage balance↗
NASA NTRS2007

Aeroelastic Model Structure Computation for Envelope Expansion

Structure detection is a procedure for selecting a subset of candidate terms, from a full model description, that best describes the observed output. This is a necessary procedure to compute an efficient system description which may afford greater insight into the functionality of the system or a simpler controller design. Structure computation as a tool for black-box modelling may be of critical importance in the development of robust, parsimonious models for the flight-test community. Moreover, this approach may lead to efficient strategies for rapid envelope expansion which may save significant development time and costs. In this study, a least absolute shrinkage and selection operator (LASSO) technique is investigated for computing efficient model descriptions of nonlinear aeroelastic systems. The LASSO minimises the residual sum of squares by the addition of an l(sub 1) penalty term on the parameter vector of the traditional 2 minimisation problem. Its use for structure detection is a natural extension of this constrained minimisation approach to pseudolinear regression problems which produces some model parameters that are exactly zero and, therefore, yields a parsimonious system description. Applicability of this technique for model structure computation for the F/A-18 Active Aeroelastic Wing using flight test data is shown for several flight conditions (Mach numbers) by identifying a parsimonious system description with a high percent fit for cross-validated data.

Kukreja, Sunil L.↗
NASA NTRS2007

Aeroelastic Model Structure Computation for Envelope Expansion

Structure detection is a procedure for selecting a subset of candidate terms, from a full model description, that best describes the observed output. This is a necessary procedure to compute an efficient system description which may afford greater insight into the functionality of the system or a simpler controller design. Structure computation as a tool for black-box modeling may be of critical importance in the development of robust, parsimonious models for the flight-test community. Moreover, this approach may lead to efficient strategies for rapid envelope expansion that may save significant development time and costs. In this study, a least absolute shrinkage and selection operator (LASSO) technique is investigated for computing efficient model descriptions of non-linear aeroelastic systems. The LASSO minimises the residual sum of squares with the addition of an l(Sub 1) penalty term on the parameter vector of the traditional l(sub 2) minimisation problem. Its use for structure detection is a natural extension of this constrained minimisation approach to pseudo-linear regression problems which produces some model parameters that are exactly zero and, therefore, yields a parsimonious system description. Applicability of this technique for model structure computation for the F/A-18 (McDonnell Douglas, now The Boeing Company, Chicago, Illinois) Active Aeroelastic Wing project using flight test data is shown for several flight conditions (Mach numbers) by identifying a parsimonious system description with a high percent fit for cross-validated data.

Kukreja, Sunil L.↗
NASA NTRSDate not supplied

Experiment Design and Visualization Techniques for an X-59 Low-boom Variability Study

This presentation outlines the design of experiments approach and data visualization techniques for a simulation study of sonic booms from NASA’s X-59 supersonic aircraft. The X-59 will soon be flown over communities across the contiguous USA as it produces a low-loudness sonic boom, or low-boom. Survey data on human perception of low-booms will be collected to support development of potential future commercial supersonic aircraft noise regulatory standards. The macroscopic atmosphere plays a critical role in the loudness of sonic booms. The extensive sonic boom simulation study presented herein was completed to assess climatological, geographical, and seasonal effects on the variability of the X-59’s low-boom loudness and noise exposure region size in order to inform X-59 community test planning. The loudness and extent of the noise exposure region make up the “sonic boom carpet.” Two spatial and temporal resolutions of atmospheric input data to the simulation were investigated. A Fast Flexible Space-Filling Design was used to select the locations across the USA for the two spatial resolutions. Analysis of simulated X-59 low-boom loudness data within a regional subset of the northeast USA was completed using a bootstrap forest to determine the final spatial and temporal resolution of the countrywide simulation study. Atmospheric profiles from NOAA’s Climate Forecast System Version 2 database were used to generate over one million simulated X-59 carpets at the final selected 138 locations across the USA. Effects of aircraft heading, season, geography, and climate zone on low-boom levels and noise exposure region size were analyzed. Models were developed to estimate loudness metrics throughout the USA for X-59 supersonic cruise overflight, and results were visualized on maps to show geographical and seasonal trends. These results inform regulators and mission planners on expected variations in boom levels and carpet extent from atmospheric variations. Understanding potential carpet variability is important when planning community noise surveys using the X-59.

X-59↗
NASA NTRSDate not supplied

The noise dose range of the X-59 estimated from propagation simulations

NASA’s X-59 aircraft will soon be flown in a series of low-boom community noise surveys across the USA. Community test experimental designs will include noise dose schedules, which require an estimate of the noise dose range that X-59 can produce. To determine the dose range, propagation simulations using NASA’s PCBoom code were completed using CFD-generated X-59 C612A near-field pressure data for an on-design condition (Mach 1.4 at 53,200 feet) and two off-design conditions (Mach 1.4 at 46,000 ft and Mach 1.3 at 43,000 ft). Near-field data at four cardinal aircraft headings were propagated through one year of realistic atmospheric profiles from the Climate Forecast System Version 2 database at several USA locations. Statistics of the mean and range of the Perceived Level (PL) of the booms in the inner 40 km of each carpet as well as the carpet width were computed. Results indicate the typical inner carpet mean PL is approximately 70-87 dB depending on the aircraft condition. The typical PL range across the inner carpet is 6-8 dB (on-design) and 5-13 dB (off-designs). The carpet widths ranged from 32-55 km. Understanding these quantities for various flight and atmospheric conditions is important for planning X-59 community noise surveys.

X-59↗
NASA NTRS1992

The EXOSAT database and archive

The EXOSAT database provides on-line access to the results and data products (spectra, images, and lightcurves) from the EXOSAT mission as well as access to data and logs from a number of other missions (such as EINSTEIN, COS-B, ROSAT, and IRAS). In addition, a number of familiar optical, infrared, and x ray catalogs, including the Hubble Space Telescope (HST) guide star catalog are available. The complete database is located at the EXOSAT observatory at ESTEC in the Netherlands and is accessible remotely via a captive account. The database management system was specifically developed to efficiently access the database and to allow the user to perform statistical studies on large samples of astronomical objects as well as to retrieve scientific and bibliographic information on single sources. The system was designed to be mission independent and includes timing, image processing, and spectral analysis packages as well as software to allow the easy transfer of analysis results and products to the user's own institute. The archive at ESTEC comprises a subset of the EXOSAT observations, stored on magnetic tape. Observations of particular interest were copied in compressed format to an optical jukebox, allowing users to retrieve and analyze selected raw data entirely from their terminals. Such analysis may be necessary if the user's needs are not accommodated by the products contained in the database (in terms of time resolution, spectral range, and the finesse of the background subtraction, for instance). Long-term archiving of the full final observation data is taking place at ESRIN in Italy as part of the ESIS program, again using optical media, and ESRIN have now assumed responsibility for distributing the data to the community. Tests showed that raw observational data (typically several tens of megabytes for a single target) can be transferred via the existing networks in reasonable time.

Reynolds, A. P.↗
NASA NTRS2005

NASA Handbook for Spacecraft Structural Dynamics Testing

Recent advances in the area of structural dynamics and vibrations, in both methodology and capability, have the potential to make spacecraft system testing more effective from technical, cost, schedule, and hardware safety points of view. However, application of these advanced test methods varies widely among the NASA Centers and their contractors. Identification and refinement of the best of these test methodologies and implementation approaches has been an objective of efforts by the Jet Propulsion Laboratory on behalf of the NASA Office of the Chief Engineer. But to develop the most appropriate overall test program for a flight project from the selection of advanced methodologies, as well as conventional test methods, spacecraft project managers and their technical staffs will need overall guidance and technical rationale. Thus, the Chief Engineer's Office has recently tasked JPL to prepare a NASA Handbook for Spacecraft Structural Dynamics Testing. An outline of the proposed handbook, with a synopsis of each section, has been developed and is presented herein. Comments on the proposed handbook are solicited from the spacecraft structural dynamics testing community.

Kern, Dennis L.↗
NASA NTRS2010

An Analysis of Rocket Propulsion Testing Costs

The primary mission at NASA Stennis Space Center (SSC) is rocket propulsion testing. Such testing is commonly characterized as one of two types: production testing for certification and acceptance of engine hardware, and developmental testing for prototype evaluation or research and development (R&D) purposes. For programmatic reasons there is a continuing need to assess and evaluate the test costs for the various types of test campaigns that involve liquid rocket propellant test articles. Presently, in fact, there is a critical need to provide guidance on what represents a best value for testing and provide some key economic insights for decision-makers within NASA and the test customers outside the Agency. Hence, selected rocket propulsion test databases and references have been evaluated and analyzed with the intent to discover correlations of technical information and test costs that could help produce more reliable and accurate cost projections in the future. The process of searching, collecting, and validating propulsion test cost information presented some unique obstacles which then led to a set of recommendations for improvement in order to facilitate future cost information gathering and analysis. In summary, this historical account and evaluation of rocket propulsion test cost information will enhance understanding of the various kinds of project cost information; identify certain trends of interest to the aerospace testing community.

Ramirez, Carmen↗
NASA NTRS2011

Venus Pressure Chamber: A Small Testing Facility Available to the Community

Venus is an inhospitable planet where the surface mean. temperature is approximately 740K and the global mean pressure is approximately 95 bars. The atmosphere is comprised mostly of CO2 (approximately 96.5%) and N2 (approximately3.5%) with trace amounts of CO and other reactive gases. Although Venus is very similar in size and mass with the Earth and is Earth's nearest planetary neighbor, it has not received many visitors from Earth, especially those that can land on the surface. The challenge most often cited for this scarcity of surface probes is the workability/survivability of instruments and equipment in Venus' harsh environment. In order to overcome this obstacle, a small pressure chamber has been acquired for use by the scientific community. It is housed at Goddard Space. Flight Center in Maryland and is available to the community for testing of small flight components, instruments and short-term experiments that require high temperatures and pressures.

Johnson, Natasha M.↗
NASA NTRS2011

A Vision of Quantitative Imaging Technology for Validation of Advanced Flight Technologies

Flight-testing is traditionally an expensive but critical element in the development and ultimate validation and certification of technologies destined for future operational capabilities. Measurements obtained in relevant flight environments also provide unique opportunities to observe flow phenomenon that are often beyond the capabilities of ground testing facilities and computational tools to simulate or duplicate. However, the challenges of minimizing vehicle weight and internal complexity as well as instrumentation bandwidth limitations often restrict the ability to make high-density, in-situ measurements with discrete sensors. Remote imaging offers a potential opportunity to noninvasively obtain such flight data in a complementary fashion. The NASA Hypersonic Thermodynamic Infrared Measurements Project has demonstrated such a capability to obtain calibrated thermal imagery on a hypersonic vehicle in flight. Through the application of existing and accessible technologies, the acreage surface temperature of the Shuttle lower surface was measured during reentry. Future hypersonic cruise vehicles, launcher configurations and reentry vehicles will, however, challenge current remote imaging capability. As NASA embarks on the design and deployment of a new Space Launch System architecture for access beyond earth orbit (and the commercial sector focused on low earth orbit), an opportunity exists to implement an imagery system and its supporting infrastructure that provides sufficient flexibility to incorporate changing technology to address the future needs of the flight test community. A long term vision is offered that supports the application of advanced multi-waveband sensing technology to aid in the development of future aerospace systems and critical technologies to enable highly responsive vehicle operations across the aerospace continuum, spanning launch, reusable space access and global reach. Motivations for development of an Agency level imagery-based measurement capability to support cross cutting applications that span the Agency mission directorates as well as meeting potential needs of the commercial sector and national interests of the Intelligence, Surveillance and Reconnaissance community are explored. A recommendation is made for an assessment study to baseline current imaging technology including the identification of future mission requirements. Development of requirements fostered by the applications suggested in this paper would be used to identify technology gaps and direct roadmapping for implementation of an affordable and sustainable next generation sensor/platform system.

Horvath, Thomas J.↗
NASA NTRS2017

A Universal Threshold for the Assessment of Load and Output Residuals of Strain-Gage Balance Data

A new universal residual threshold for the detection of load and gage output residual outliers of wind tunnel strain{gage balance data was developed. The threshold works with both the Iterative and Non{Iterative Methods that are used in the aerospace testing community to analyze and process balance data. It also supports all known load and gage output formats that are traditionally used to describe balance data. The threshold's definition is based on an empirical electrical constant. First, the constant is used to construct a threshold for the assessment of gage output residuals. Then, the related threshold for the assessment of load residuals is obtained by multiplying the empirical electrical constant with the sum of the absolute values of all first partial derivatives of a given load component. The empirical constant equals 2.5 microV/V for the assessment of balance calibration or check load data residuals. A value of 0.5 microV/V is recommended for the evaluation of repeat point residuals because, by design, the calculation of these residuals removes errors that are associated with the regression analysis of the data itself. Data from a calibration of a six-component force balance is used to illustrate the application of the new threshold definitions to real{world balance calibration data.

wind tunnel balance↗
NASA NTRS2017

Wind Tunnel Strain-Gage Balance Calibration Data Analysis Using a Weighted Least Squares Approach

A new approach is presented that uses a weighted least squares fit to analyze wind tunnel strain-gage balance calibration data. The weighted least squares fit is specifically designed to increase the influence of single-component loadings during the regression analysis. The weighted least squares fit also reduces the impact of calibration load schedule asymmetries on the predicted primary sensitivities of the balance gages. A weighting factor between zero and one is assigned to each calibration data point that depends on a simple count of its intentionally loaded load components or gages. The greater the number of a data point's intentionally loaded load components or gages is, the smaller its weighting factor becomes. The proposed approach is applicable to both the Iterative and Non-Iterative Methods that are used for the analysis of strain-gage balance calibration data in the aerospace testing community. The Iterative Method uses a reasonable estimate of the tare corrected load set as input for the determination of the weighting factors. The Non-Iterative Method, on the other hand, uses gage output differences relative to the natural zeros as input for the determination of the weighting factors. Machine calibration data of a six-component force balance is used to illustrate benefits of the proposed weighted least squares fit. In addition, a detailed derivation of the PRESS residuals associated with a weighted least squares fit is given in the appendices of the paper as this information could not be found in the literature. These PRESS residuals may be needed to evaluate the predictive capabilities of the final regression models that result from a weighted least squares fit of the balance calibration data.

calibration analysis↗
NASA NTRS2018

Collaborative Experiments and Computations in Aircraft Icing

The formation of ice over lifting surfaces can affect aerodynamic performance. The ability to predict ice accumulation and the resulting degradation in vehicle performance is essential to determine the limitations of aircraft in icing encounters. The consequences of underestimating performance degradation can be serious and so it is important to produce accurate predictions, particularly for severe icing conditions. The simulation of ice accretion is a challenging multidisciplinary problem that requires close collaboration between the computational and ground test communities. This paper describes three recent case studies and the lessons learned through collaborative experiments and computations in aircraft icing- one for large commercial transports, one for rotorcraft, and one dealing with icing on regional jets.

and rotorcraft↗
NASA NTRS2017

Guide for Pressure-Sensitive Paint Testing at NASA Ames Research Center Unitary Plan Wind Tunnel

Optical measurement techniques have become a standard option for wind tunnel tests. Pressure-sensitive paint (PSP) is a mature test technique and a common experimental technique in many wind tunnels to measure the global mean static pressure on a model. PSP is a valuable tool when a more detailed distribution of the pressure is needed rather than the conventional pressure taps alone. Planning for a test with optical-based techniques can present new challenges even for experienced customer. The purpose of this paper is to provide a resource to the wind tunnel testing community and customers interested in obtaining PSP measurements on a wind tunnel model at the NASA Ames Research Center’s Unitary Plan Wind Tunnel. An overview of PSP mechanics, a list of requirements for ones considering PSP measurements, and PSP deliverable details are specified.

Unitary↗