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NASA NTRS2012

Hardware QA: Preparing and Certifying a Rover to Land on the Surface of Mars

The Mars Science Laboratory Project presented multiple challenges of complexity for hardware QA personnel. Technical complexity was a major challenge. This is a one-of-kind never-before-been-built Spacecraft with a nuclear-powered Rover the size of a small SUV. It features a never-before-been-used Skycrane landing system featuring a Descent Stage which is a complex spacecraft within itself. Equally complex was figuring out how to support multiple activities at multiple facilities in this country and around the world at the same time.

technical challenges↗

NASA NTRSDate not supplied

Downfolding Complex Materials Problems Onto Model Hamiltonians for Quantum Computers

Simulating the properties of quantum materials is expected to be one of the exciting applications for quantum computers and where we hope to see advantages over classical hardware. The complexity of ab initio Hamiltonians describing the physics of application-relevant materials places them beyond the realm of possibility for solution on near-term hardware with a limited number of qubits. Various Hamiltonian approximations, including Hamiltonian downfolding, offers a possibility towards simulating complex materials on near-term hardware. This is accomplished by approximating the relevant physics of a given material through their representation by simpler model Hamiltonians, such as the Hubbard Hamiltonian or extensions of it. Here we employ a well-defined first-principles methodology for deriving downfolded multi-band extended Hubbard Hamiltonians of materials, capturing strong electronic correlation and electron-phonon coupling, based on the formalism of Wannier functions and the calculation of the screened Coulomb interaction. We demonstrate for a variety of systems that quantum simulation of these downfolded Hamiltonians reproduces key properties, thus establishing downfolding as a promising route to achieve near-term simulation of application-relevant systems on quantum hardware.

Antonios Markos Alvertis↗

NASA NTRSDate not supplied

Downfolding complex materials problems onto model Hamiltonians for quantum computers

Antonios M. Alvertis↗

NASA NTRS1998

FPGA Based Reconfigurable ATM Switch Test Bed

Various issues associated with "FPGA Based Reconfigurable ATM Switch Test Bed" are presented in viewgraph form. Specific topics include: 1) Network performance evaluation; 2) traditional approaches; 3) software simulation; 4) hardware emulation; 5) test bed highlights; 6) design environment; 7) test bed architecture; 8) abstract sheared-memory switch; 9) detailed switch diagram; 10) traffic generator; 11) data collection circuit and user interface; 12) initial results; and 13) the following conclusions: Advances in FPGA make hardware emulation feasible for performance evaluation, hardware emulation can provide several orders of magnitude speed-up over software simulation; due to the complexity of hardware synthesis process, development in emulation is much more difficult than simulation and requires knowledge in both networks and digital design.

Chu, Pong P.↗

NASA NTRS1965

Contamination analysis and monitoring

"Sterilization" is a term applied to any process or procedure that produces a condition of sterility. Sterility is an absolute concept and refers to the destruction or removal of all life. However, when sterility as an absolute concept is applied to the sterilization of space hardware, it ceases to be operational. Absolute proof of sterility of flight hardware is impossible. Hence, for an operational approach to certification of sterility of space hardware, it is necessary to apply the probability concept. The present report is concerned with the applicability of mathematics to predict the probability of achieving sterility in a complex space hardware system. As such, this approach is concerned with the manipulation of microbiological data rather than mathematical rigor.

contamination↗

NASA NTRS2008

Managing Complexity in Next Generation Robotic Spacecraft: From a Software Perspective

This presentation highlights the challenges in the design of software to support robotic spacecraft. Robotic spacecraft offer a higher degree of autonomy, however currently more capabilities are required, primarily in the software, while providing the same or higher degree of reliability. The complexity of designing such an autonomous system is great, particularly while attempting to address the needs for increased capabilities and high reliability without increased needs for time or money. The efforts to develop programming models for the new hardware and the integration of software architecture are highlighted.

Multi - threaded programming↗

NASA NTRSDate not supplied

Having a Come-Apart: Lessons Learned from Additively Manufactured Hardware Failures

NASA has been engaged with additively manufactured (AM) process and component development since the 2000’s. AM offers various technical advantages, such as enhanced hardware design complexity, part consolidation, and processing of novel alloys in addition to programmatic advantages for reduction in processing time and cost. The focus of much of the AM development at NASA has been to mature the various processes, characterize material properties, develop standards, produce demonstrator parts, and integrate AM hardware in liquid rocket engines. These aspects have been demonstrated through process and design iterations using a methodical characterization, test-fail-fix cycles, as well as application and dissemination of lessons learned. In addition to these fundamental demonstrations of the AM process and hardware development, alloys that provide performance advantages in the high temperature and high-pressure environments have been matured for use in rocket engines. These environments are challenging for any alloy and any design, and the AM process is required to fully meet the intended design requirements. The importance of proper AM process was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality resulted from an AM process issue. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. In part, such concerns motivate the AM certification approach that NASA has recently adopted in NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems”. This presentation provides an overview of the previously mentioned failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. The objective of this presentation is to provide awareness to the community working critical and non-critical AM components and the lessons learned on proper implementation of AM.

Additive Manufacturing↗

NASA NTRS2012

Development and Testing of Molecular Adsorber Coatings

The effect of on-orbit molecular contamination has the potential to degrade the performance of spaceflight hardware and diminish the lifetime of the spacecraft. For example, sensitive surfaces, such as optical surfaces, electronics, detectors, and thermal control surfaces, are vulnerable to the damaging effects of contamination from outgassed materials. The current solution to protect these surfaces is through the use of zeolite coated ceramic adsorber pucks. However, these pucks and its additional complex mounting hardware requirements result in several disadvantages, such as size, weight, and cost related concerns, that impact the spacecraft design and the integration and test schedule. As a result, a new innovative molecular adsorber coating was developed as a sprayable alternative to mitigate the risk of on-orbit molecular contamination. In this study, the formulation for molecular adsorber coatings was optimized using various binders, pigment treatment methods, binder to pigment ratios, thicknesses, and spray application techniques. The formulations that passed coating adhesion and vacuum thermal cycling tests were further tested for its adsorptive capacity. Accelerated molecular capacitance tests were performed in an innovatively designed multi-unit system containing idealized contaminant sources. This novel system significantly increased the productivity of the testing phase for the various formulations that were developed. Work performed during the development and testing phases has demonstrated successful application of molecular adsorber coatings onto metallic substrates, as well as, very promising results for the adhesion performance and the molecular capacitance of the coating. Continued testing will assist in the qualification of molecular adsorber coatings for use on future contamination sensitive spaceflight missions.

Abraham, Nithin↗

NASA NTRS2008

Testing Microshutter Arrays Using Commercial FPGA Hardware

NASA is developing micro-shutter arrays for the Near Infrared Spectrometer (NIRSpec) instrument on the James Webb Space Telescope (JWST). These micro-shutter arrays allow NIRspec to do Multi Object Spectroscopy, a key part of the mission. Each array consists of 62414 individual 100 x 200 micron shutters. These shutters are magnetically opened and held electrostatically. Individual shutters are then programmatically closed using a simple row/column addressing technique. A common approach to provide these data/clock patterns is to use a Field Programmable Gate Array (FPGA). Such devices require complex VHSIC Hardware Description Language (VHDL) programming and custom electronic hardware. Due to JWST's rapid schedule on the development of the micro-shutters, rapid changes were required to the FPGA code to facilitate new approaches being discovered to optimize the array performance. Such rapid changes simply could not be made using conventional VHDL programming. Subsequently, National Instruments introduced an FPGA product that could be programmed through a Labview interface. Because Labview programming is considerably easier than VHDL programming, this method was adopted and brought success. The software/hardware allowed the rapid change the FPGA code and timely results of new micro-shutter array performance data. As a result, numerous labor hours and money to the project were conserved.

Rapchun, David↗

NASA NTRS1985

Space salvage - A report on Shuttle mission STS 51-A

The success of the Space Shuttle Orbiter and Manned Maneuvering Unit (MMU) in the rendezvous and capture of the Westar and Palapa satellites was largely attributable to the availability and fidelity of numerous simulators, which facilitated real time development and verification of satellite rescue procedures and hardware. This complex Space Shuttle mission, STS 51-A, was developed and executed in only 8 months; by contrast, the Solar Maximum repair mission was developed over a period of three years. Attention is presently given to Orbiter sensors, satellite night stationkeeping, satellite stabilization tasks, MMU tasks, and preparatory simulations.

Hauck, F. H.↗

NASA NTRS1987

FLUINT - General fluid system analysis with SINDA '85

This paper introduces FLUINT (FLUid INTegrator), a general fluid system simulation program that works in conjunction with SINDA '85 (Systems Improved Numerical Differencing Analyzer, 1985 version). FLUINT solves arbitrary networks representing internal fluid systems while SINDA '85 simultaneously solves traditional thermal networks. This transportable program is intended to provide spacecraft thermal management engineers with the analytic tools needed to simulate single- and two-phase coolant loops. The fundamental concepts for fluid system modeling are described, and methods of modeling complex, hardware-specific components are outlined. Underlying correlations and solution methods are briefly discussed. Example analyses and comparisons to test data are provided.

Cullimore, B. A.↗

NASA NTRS1992

Creating an open environment software infrastructure

As the development of complex computer hardware accelerates at increasing rates, the ability of software to keep pace is essential. The development of software design tools, however, is falling behind the development of hardware for several reasons, the most prominent of which is the lack of a software infrastructure to provide an integrated environment for all parts of a software system. The research was undertaken to provide a basis for answering this problem by investigating the requirements of open environments.

Jipping, Michael J.↗

NASA NTRS1991

Evaluating robot procedures and tasks for the flight telerobotic servicer

NASA is developing space telerobotic systems to construct, service and maintain complex space hardware. These systems will be controlled by an astronaut operator in space. Preliminary mission procedures have been developed and typical task elements have been selected. The present study simulates some of these procedures, tasks and devices in the laboratory in order to obtain initial operator/robot system performance data.

Sauerwein, Timothy A.↗

NASA NTRS1985

Development of an Expert System for Representing Procedural Knowledge

A high level of automation is of paramount importance in most space operations. It is critical for unmanned missions and greatly increases the effectiveness of manned missions. However, although many functions can be automated by using advanced engineering techniques, others require complex reasoning, sensing, and manipulatory capabilities that go beyond this technology. Automation of fault diagnosis and malfunction handling is a case in point. The military have long been interested in this problem, and have developed automatic test equipment to aid in the maintenance of complex military hardware. These systems are all based on conventional software and engineering techniques. However, the effectiveness of such test equipment is severely limited. The equipment is inflexible and unresponsive to the skill level of the technicians using it. The diagnostic procedures cannot be matched to the exigencies of the current situation nor can they cope with reconfiguration or modification of the items under test. The diagnosis cannot be guided by useful advice from technicians and, when a fault cannot be isolated, no explanation is given as to the cause of failure. Because these systems perform a prescribed sequence of tests, they cannot utilize knowledge of a particular situation to focus attention on more likely trouble spots. Consequently, real-time performance is highly unsatisfactory. Furthermore, the cost of developing test software is substantial and time to maturation is excessive. Significant advances in artificial intelligence (AI) have recently led to the development of powerful and flexible reasoning systems, known as expert or knowledge-based systems. We have devised a powerful and theoretically sound scheme for representing and reasoning about procedural knowledge.

Georgeff, Michael P.↗

NASA NTRS2001

ISS Microgravity Research Payload Training Methodology

The NASA Microgravity Research Discipline has multiple categories of science payloads that are being planned and currently under development to operate on various ISS on-orbit increments. The current program includes six subdisciplines; Materials Science, Fluids Physics, Combustion Science, Fundamental Physics, Cellular Biology and Macromolecular Biotechnology. All of these experiment payloads will require the astronaut various degrees of crew interaction and science observation. With the current programs planning to build various facility class science racks, the crew will need to be trained on basic core operations as well as science background. In addition, many disciplines will use the Express Rack and the Microgravity Science Glovebox (MSG) to utilize the accommodations provided by these facilities for smaller and less complex type hardware. The Microgravity disciplines will be responsible to have a training program designed to maximize the experiment and hardware throughput as well as being prepared for various contingencies both with anomalies as well as unexpected experiment observations. The crewmembers will need various levels of training from simple tasks as power on and activate to extensive training on hardware mode change out to observing the cell growth of various types of tissue cultures. Sample replacement will be required for furnaces and combustion type modules. The Fundamental Physics program will need crew EVA support to provide module change out of experiment. Training will take place various research centers and hardware development locations. It is expected that onboard training through various methods and video/digital technology as well as limited telecommunication interaction. Since hardware will be designed to operate from a few weeks to multiple research increments, flexibility must be planned in the training approach and procedure skills to optimize the output as well as the equipment maintainability. Early increment lessons learned will be addressed.

Schlagheck, Ronald↗

NASA NTRS2002

ANTS: Applying A New Paradigm for Lunar and Planetary Exploration

ANTS (Autonomous Nano- Technology Swarm), a mission architecture consisting of a large (1000 member) swarm of picoclass (1 kg) totally autonomous spacecraft with both adaptable and evolvable heuristic systems, is being developed as a NASA advanced mission concept, and is here examined as a paradigm for lunar surface exploration. As the capacity and complexity of hardware and software, demands for bandwidth, and the sophistication of goals for lunar and planetary exploration have increased, greater cost constraints have led to fewer resources and thus, the need to operate spacecraft with less frequent human contact. At present, autonomous operation of spacecraft systems allows great capability of spacecraft to 'safe' themselves and survive when conditions threaten spacecraft safety. To further develop spacecraft capability, NASA is at the forefront of development of new mission architectures which involve the use of Intelligent Software Agents (ISAs), performing experiments in space and on the ground to advance deliberative and collaborative autonomous control techniques. Selected missions in current planning stages require small groups of spacecraft weighing tens, instead of hundreds, of kilograms to cooperate at a tactical level to select and schedule measurements to be made by appropriate instruments onboard. Such missions will be characterizing rapidly unfolding real-time events on a routine basis. The next level of development, which we are considering here, is in the use of autonomous systems at the strategic level, to explore the remote terranes, potentially involving large surveys or detailed reconnaissance.

Clark, P. E.↗

NASA NTRS2003

Self-Reacting Friction Stir Welding for Aluminum Complex Curvature Applications

This viewgraph representation provides an overview of sucessful research conducted by Lockheed Martin and NASA to develop an advanced self-reacting friction stir technology for complex curvature aluminum alloys. The research included weld process development for 0.320 inch Al 2219, sucessful transfer from the 'lab' scale to the production scale tool and weld quality exceeding strenght goals. This process will enable development and implementation of large scale complex geometry hardware fabrication. Topics covered include: weld process development, weld process transfer, and intermediate hardware fabrication.

Brown, Randy J.↗

NASA NTRS2003

SLI Complex Curvature Friction Stir Weld Risk Reduction Program

The Space Launch Initiative Program (SLI) in conjunction with the National Center for Advanced Manufacturing (NCAM) will demonstrate the ability to produce large-scale complex curvature hardware using the self-reacting friction stir welding process. This multi-phased risk reduction program includes friction stir welding process development and manufacture of a 22-ft diameter quarter dome using a conventional tooling approach; it culminates in a 27.5-ft diameter quarter dome demonstration performed on a 5-axis Universal Weld System. The design, fabrication, and installation of the Universal Weld System is made possible through a collaboration between the State of Louisiana, NASA, and the University of New Orleans. The Universal Weld System, manufactured by MTS Systems Corporation, will be installed at the Michoud Assembly Facility in New Orleans, Louisiana, and will be capable of manufacturing domes up to 30 ft in diameter. All welding will be accomplished using the Adaptable Adjustable Pin Tool (AdAPT) weld head and controller manufactured by MTS. Weld parameters will be developed for an aluminum alloy in gauges ranging from 0.320 to 0.400 in. thick. Weld quality will be verified through radiography, mechanical property testing at ambient and LN2 temperatures, and metallurgical analysis. The AdAPT weld head will then be mounted on a 22-ft diameter dome tool, which will be modified to include a welding track and drive system for moving the AdAPT weld head along the weld joint. This tool will then be used to manufacture a 22-ft diameter dome of an aluminum alloy, with 0.320-in. constant thickness joints, consisting of three individual gore panels. Finally, the 27.5-ft diameter quarter dome will be welded on the Universal Weld System. The quarter dome will consist of three individual gore panels with weld lands tapering from 0.320 to 0.360 in. in thickness. With the demonstration of these welds, the ability to manufacture large diameter domes using the friction stir weld process in conjunction with a universal weld system provides a low risk approach to the fabrication of aluminum tanks for future launch vehicle applications.

Hartley, Paula J.↗