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NASA NTRS2014

NASA's Space Launch System: Momentum Builds Toward First Launch

NASA's Space Launch System (SLS) is gaining momentum toward the first launch of a new exploration-class heavy lift launch vehicle for international exploration and science initiatives. The SLS comprises an architecture that begins with a vehicle capable of launching 70 metric tons (t) into low Earth orbit. It will launch the Orion Multi-Purpose Crew Vehicle (MPCV) on its first autonomous flight beyond the Moon and back in December 2017. Its first crewed flight follows in 2021. SLS can evolve to a130-t lift capability and serve as a baseline for numerous robotic and human missions ranging from a Mars sample return to delivering the first astronauts to explore another planet. The SLS Program formally transitioned from the formulation phase to implementation with the successful completion of the rigorous Key Decision Point C review in 2014. As a result, the Agency authorized the Program to move forward to Critical Design Review, scheduled for 2015. In the NASA project life cycle process, SLS has completed 50 percent of its major milestones toward first flight. Every SLS element manufactured development hardware for testing over the past year. Accomplishments during 2013/2014 included manufacture of core stage test articles, preparations for qualification testing the solid rocket boosters and the RS-25 main engines, and shipment of the first flight hardware in preparation for the Exploration Flight Test-1 (EFT-1) in 2014. SLS was conceived with the goals of safety, affordability, and sustainability, while also providing unprecedented capability for human exploration and scientific discovery beyond Earth orbit. In an environment of economic challenges, the SLS team continues to meet ambitious budget and schedule targets through the studied use of hardware, infrastructure, and workforce investments the United States made in the last half century, while selectively using new technologies for design, manufacturing, and testing, as well as streamlined management approaches that have increased decision velocity and reduced associated costs. This paper will summarize recent SLS Program accomplishments, as well as the challenges and opportunities ahead for the most powerful and capable launch vehicle in history.

May, Todd A.↗

NASA NTRS1992

An environmental testing facility for Space Station Freedom power management and distribution hardware

The plans for a new test facility, including new environmental test systems, which are presently under construction, and the major environmental Test Support Equipment (TSE) used therein are addressed. This all-new Rocketdyne facility will perform space simulation environmental tests on Power Management and Distribution (PMAD) hardware to Space Station Freedom (SSF) at the Engineering Model, Qualification Model, and Flight Model levels of fidelity. Testing will include Random Vibration in three axes - Thermal Vacuum, Thermal Cycling and Thermal Burn-in - as well as numerous electrical functional tests. The facility is designed to support a relatively high throughput of hardware under test, while maintaining the high standards required for a man-rated space program.

Jackola, Arthur S.↗

NASA NTRS1976

Development of a self contained heat rejection module, phase 2 and 3

This is the final report for Phases II and III of the Development of a Self Contained Heat Rejection Module Program conducted under NASA contract NAS9-14408. The objective of this program was to perform detail design and construct a prototype test article Self Contained Heat Rejection Module (SHRM). Also to install this test article in the NASA/JSC Space Environment Simulation Laboratory Chamber A and conduct thermal vacuum demonstration and performance testing. The end product of this contract was the prototype hardware, the test article and the test results.

M L Fleming↗

NASA NTRS1994

Porous tube plant nutrient delivery system development: A device for nutrient delivery in microgravity

The Porous Tube Plant Nutrient Delivery Systems or PTPNDS (U.S. Patent #4,926,585) has been under development for the past six years with the goal of providing a means for culturing plants in microgravity, specifically providing water and nutrients to the roots. Direct applications of the PTPNDS include plant space biology investigations on the Space Shuttle and plant research for life support in the Space Station Freedom. In the past, we investigated various configurations, the suitability of different porous materials, and the effects of pressure and pore size on plant growth. Current work is focused on characterizing the physical operation of the system, examining the effects of solution aeration, and developing prototype configurations for the Plant Growth Unit (PGU), the flight system for the Shuttle mid-deck. Future developments will involve testing on KC-135 parabolic flights, the design of flight hardware and testing aboard the Space Shuttle.

Dreschel, T. W.↗

NASA NTRS2019

James Webb Space Telescope Optical Telescope Element / Integrated Science Instrument Module (OTIS) Cryogenic Vacuum Test Part I: Thermal Architecture

The James Webb Space Telescope (JWST), set to launch in early 2019, is currently undergoing a series of system-level environmental tests to verify its workmanship and end-to-end functionality. As part of this series, the Optical Telescope Element and Integrated Science Instrument Module (OTIS) Cryo-Vacuum (CV) test, the most complex cryogenic test executed to date by NASA, was completed in 2017 at the Johnson Space Center's Chamber A facility. The OTIS CV test was intended as a comprehensive test of the integrated instrument and telescope systems to fully understand its optical, structural, and thermal performance within its intended flight environment. Due to its complexity, extensive pre-test planning was required to ensure payload safety and compliance with all limits and constraints. A comprehensive thermal analysis campaign was undertaken to predict the behavior of the test payload during its transition to cryogenic temperatures and back to ambient, and exhaustive preparations for off-nominal scenarios were studied due to the increased possibility of unanticipated events during the 100-day test length. This current four-part online course for the NASA Engineering and Safety Center (NESC) Academy gives a thorough overview of the mutiple years of preparation executed by hundreds of individuals to ensure the success of the JWST OTIS CV Test. Part I will introduce the major components of James Webb and specifically the OTIS CV Test thermal architecture. Part II will encompass the extensive thermal analysis performed to prepare for the test. Part III will talk about the preparations for off-nominal events: what analysis was done, and how steps were taken pre-test to anticipate unexpected circumstances and mitigate their impacts to hardware and test timeline. Part IV is a recap of the lessons learned from the thermal perspective for both the payload and ground support equipment (GSE) test conductors. It is hoped that the insight gained from the OTIS CV test campaign will benefit planning and execution for upcoming large cryogenic missions.

OTIS↗

NASA NTRS2019

James Webb Space Telescope Optical Telescope Element / Integrated Science Instrument Module (OTIS) Cryogenic Vacuum Test Part II: Thermal Analysis

The James Webb Space Telescope (JWST), set to launch in early 2019, is currently undergoing a series of system-level environmental tests to verify its workmanship and end-to-end functionality. As part of this series, the Optical Telescope Element and Integrated Science Instrument Module (OTIS) Cryo-Vacuum (CV) test, the most complex cryogenic test executed to date by NASA, was completed in 2017 at the Johnson Space Center's Chamber A facility. The OTIS CV test was intended as a comprehensive test of the integrated instrument and telescope systems to fully understand its optical, structural, and thermal performance within its intended flight environment. Due to its complexity, extensive pre-test planning was required to ensure payload safety and compliance with all limits and constraints. A comprehensive thermal analysis campaign was undertaken to predict the behavior of the test payload during its transition to cryogenic temperatures and back to ambient, and exhaustive preparations for off-nominal scenarios were studied due to the increased possibility of unanticipated events during the 100-day test length. This current four-part online course for the NASA Engineering and Safety Center (NESC) Academy gives a thorough overview of the multiple years of preparation executed by hundreds of individuals to ensure the success of the JWST OTIS CV Test. Part I will introduce the major components of James Webb and specifically the OTIS CV Test thermal architecture. Part II will encompass the extensive thermal analysis performed to prepare for the test. Part III will talk about the preparations for off-nominal events: what analysis was done, and how steps were taken pre-test to anticipate unexpected circumstances and mitigate their impacts to hardware and test timeline. Part IV is a recap of the lessons learned from the thermal perspective for both the payload and ground support equipment (GSE) test conductors. It is hoped that the insight gained from the OTIS CV test campaign will benefit planning and execution for upcoming large cryogenic missions.

Testing↗

NASA NTRS1978

TDRSS system configuration study for space shuttle program

This study was set up to assure that operation of the shuttle orbiter communications systems met the program requirements when subjected to electrical conditions similar to those which will be encountered during the operational mission. The test program intended to implement an integrated test bed, consisting of applicable orbiter, EVA, payload simulator, STDN, and AF/SCF, as well as the TDRSS equipment. The stated intention of Task 501 Program was to configure the test bed with prototype hardware for a system development test and production hardware for a system verification test. In case of TDRSS when the hardware was not available, simulators whose functional performance was certified to meet appropriate end item specification were used.

Source record↗

NASA NTRS2008

Smart Sensor Systems for Aerospace Applications: From Sensor Development to Application Testing

The application of Smart Sensor Systems for aerospace applications is a multidisciplinary process consisting of sensor element development, element integration into Smart Sensor hardware, and testing of the resulting sensor systems in application environments. This paper provides a cross-section of these activities for multiple aerospace applications illustrating the technology challenges involved. The development and application testing topics discussed are: 1) The broadening of sensitivity and operational range of silicon carbide (SiC) Schottky gas sensor elements; 2) Integration of fire detection sensor technology into a "Lick and Stick" Smart Sensor hardware platform for Crew Exploration Vehicle applications; 3) Extended testing for zirconia based oxygen sensors in the basic "Lick and Stick" platform for environmental monitoring applications. It is concluded that that both core sensor platform technology and a basic hardware platform can enhance the viability of implementing smart sensor systems in aerospace applications.

Hunter, G. W.↗

NASA NTRS1992

Status of the variable diameter centerbody inlet program

The Variable Diameter Centerbody (VDC) inlet is an ongoing research program at LeRC. The VDC inlet is a mixed compression, axisymmetric inlet that has potential application on the next generation supersonic transport. This inlet was identified as one of the most promising axisymmetric concepts for supersonic cruise aircraft during the SCAR program in the late 1970's. Some of its features include high recovery, low bleed, good angle-of-attack tolerance, and excellent engine airflow matching. These features were demonstrated at LeRC in the past by the design and testing of fixed hardware models. A current test program in the LeRC 10' x 10' Supersonic Wind Tunnel (SWT) will attempt to duplicate these features on model hardware that actually incorporates a flight-like variable diameter centerbody mechanism.

Saunders, John D.↗

NASA NTRS2004

Evaluation of Open-Source Hard Real Time Software Packages

Reliable software is, at times, hard to find. No piece of software can be guaranteed to work in every situation that may arise during its use here at Glenn Research Center or in space. The job of the Software Assurance (SA) group in the Risk Management Office is to rigorously test the software in an effort to ensure it matches the contract specifications. In some cases the SA team also researches new alternatives for selected software packages. This testing and research is an integral part of the department of Safety and Mission Assurance. Real Time operation in reference to a computer system is a particular style of handing the timing and manner with which inputs and outputs are handled. A real time system executes these commands and appropriate processing within a defined timing constraint. Within this definition there are two other classifications of real time systems: hard and soft. A soft real time system is one in which if the particular timing constraints are not rigidly met there will be no critical results. On the other hand, a hard real time system is one in which if the timing constraints are not met the results could be catastrophic. An example of a soft real time system is a DVD decoder. If the particular piece of data from the input is not decoded and displayed to the screen at exactly the correct moment nothing critical will become of it, the user may not even notice it. However, a hard real time system is needed to control the timing of fuel injections or steering on the Space Shuttle; a delay of even a fraction of a second could be catastrophic in such a complex system. The current real time system employed by most NASA projects is Wind River's VxWorks operating system. This is a proprietary operating system that can be configured to work with many of NASA s needs and it provides very accurate and reliable hard real time performance. The down side is that since it is a proprietary operating system it is also costly to implement. The prospect of replacing this somewhat costly implementation is the focus of one of the SA group s current research projects. The explosion of open source software in the last ten years has led to the development of a multitude of software solutions which were once only produced by major corporations. The benefits of these open projects include faster release and bug patching cycles as well as inexpensive if not free software solutions. The main packages for hard real time solutions under Linux are Real Time Application Interface (RTAI) and two varieties of Real Time Linux (RTL), RTLFree and RTLPro. During my time here at NASA I have been testing various hard real time solutions operating as layers on the Linux Operating System. All testing is being run on an Intel SBC 2590 which is a common embedded hardware platform. The test plan was provided to me by the Software Assurance group at the start of my internship and my job has been to test the systems by developing and executing the test cases on the hardware. These tests are constructed so that the Software Assurance group can get hard test data for a comparison between the open source and proprietary implementations of hard real time solutions.

Mattei, Nicholas S.↗

NASA NTRS2013

Dry wind tunnel system

This invention is a ground flutter testing system without a wind tunnel, called Dry Wind Tunnel (DWT) System. The DWT system consists of a Ground Vibration Test (GVT) hardware system, a multiple input multiple output (MIMO) force controller software, and a real-time unsteady aerodynamic force generation software, that is developed from an aerodynamic reduced order model (ROM). The ground flutter test using the DWT System operates on a real structural model, therefore no scaled-down structural model, which is required by the conventional wind tunnel flutter test, is involved. Furthermore, the impact of the structural nonlinearities on the aeroelastic stability can be included automatically. Moreover, the aeroservoelastic characteristics of the aircraft can be easily measured by simply including the flight control system in-the-loop. In addition, the unsteady aerodynamics generated computationally is interference-free from the wind tunnel walls. Finally, the DWT System can be conveniently and inexpensively carried out as a post GVT test with the same hardware, only with some possible rearrangement of the shakers and the inclusion of additional sensors.

Chen, Ping-Chih↗

NASA NTRS1997

Acoustic Testing of the Cassini Spacecraft and Titan 4 Payload Fairing: Introduction and Test Configuration - Part 1

NASA Lewis Research Center recently led a multi-organizational acoustic test program. This testing consisted of acoustically exciting a Cassini spacecraft simulator in a full scale 60 foot high Titan 4 payload fairing with various acoustic blanket designs and configurations in a large reverberant acoustic chamber. The primary purpose of this test program was to measure the fairing's internal acoustics and spacecraft vibration, especially the Radioisotope Thermoelectric Generators (RTG) vibration, and to quantify the mitigation efforts in reducing these levels. Key to this reduction effort was the utilization of new acoustic blanket designs. This paper will provide the background and rationale for performing this test program, state the test program's primary and secondary objectives and describe the test matrix, hardware and instrumentation. A second part companion paper will provide the test results and data analysis.

Hughes, William O.↗

NASA NTRS2004

Evaluation of Pulsed Plasma Thruster Micropulsing

This paper evaluates the concept of pulsed plasma thruster (PPT) micropulsing. Micropulsing was a premise behind a power processing unit (PPU) and an energy storage unit (ESU) design that for certain mission profiles, it was advantageous to operate a PPT at lower energy but higher frequency rather than at a higher energy but lower frequency. This premise allows for reductions in the ESU volume and mass without paying a penalty in thrust. To complete the evaluation, an independent spark plug initiation unit, a high voltage power supply and a variety of mica foil capacitors at 2.6, 5, 10, and 20 capacitance were used to conduct a series of tests on a single PPT to map performance levels of thrust, impulse bit, efficiency and specific impulse over a comparable power range. Testing at NASA Glenn Research Center was conducted with breadboard PPT hardware. The test results showed that operating in the lower energy ESU micropulsing mode produced similar thrust levels to a higher energy ESU operating at high power level. Further testing however showed a reduction in specific impulse and efficiency when the smaller capacitances were used at the highest power levels. This would require more fuel mass for a mission that was predominately high power, potentially negating the ESU mass savings. Therefore, micropulsing is advantageous where most of a mission profile occurs at low power, but retains the ability to conduct high thrust maneuvers when necessary.

Arrington, Lynn↗

NASA NTRSDate not supplied

Thermal Protection Materials and Systems at NASA Ames Research Center

Thermal Protection Systems (TPS) are critical for enabling NASA missions involving high-speed atmospheric flight where the entries usually include descending into the atmosphere followed by a trajectory that aims to burn off energy and result in a controlled landing. NASA Ames focuses on qualifying and certifying TPS for current missions, sustaining TPS for future missions, and developing new TPS for upcoming missions where a heritage solution is not viable. More recently there is also a focus on advancing and transferring technologies that can benefit both commercial and government space needs.Developing mature thermal protection systems is a lengthy process involving advanced tools, extensive research, and testing. Design and analysis tools are used to predict aerothermal environments, aid the design of test and flight hardware, and support the testing for the thermal/mechanical response of thermal protection systems. More recently, advances in computational methods help reduce the time and cost of technological advances, aid in optimized material architecture design, and improve material properties and performance. While high-enthalpy testing that simulates the conditions of space flight remains essential for the evaluation and development of TPS materials, computational tools are already showing promise in reducing the need for widespread testing and can help fast-trackthe design cycle.With the exploration of new destinations EDL instrumentation remains an important element of the heatshield and NASA Ames and partners have developed and delivered instrumentation flight hardware in support of recent Mars missions,including Mars Science Lab (MSL) and Mars 2020 (M2020),as well as Artemis Orion. Sensors installed on the heatshield and backshell of spacecraft provide coveted information about the aerodynamic and aerothermal environment during entry.Overthe years NASA Ames has brought several reusable and ablative TPS materials to a level of readiness to hand off to missions and the Thermal Protection Materials branch continues to serve as a TPS steward for the agency.

Thermal protection materials↗

DOE OSTI2023

Performance assessment of a real water source heat pump within a hardware-in-the-loop (HIL) testing environment

Over the last decade, the global fight against climate change through electrification has led to an increase in research on building heating, ventilation, and air conditioning (HVAC) systems that utilize intelligent control algorithms to provide demand-side grid service while also maintaining the thermal comfort of building occupants. As the pivotal point between building electricity consumption and indoor thermal comfort, high-efficiency electrical vapor-compression heat pumps are at the center of these emerging studies, and various grid-interactive and occupant-comfort control algorithms have been developed for them. The impact of these algorithms on heat pump operation and performance when subjected to different weather conditions, building loads, and grid requests calls for investigation and verification via experimental testing with actual heat pumps integrated with real-time building and grid responses. This study introduces a Water-Source Heat Pump (WSHP) Hardware-in-The-Loop (HIL) Test Facility that is the first of its kind. This testbed utilizes a 2-ton variable speed water-to-air heat pump that is capable of interacting with a virtual environment currently comprised of an EnergyPlus (E+) building simulation, an agent-based occupant behavioral model, and a single U-tube ground-loop heat exchanger (GLHE) model. Detailed descriptions of the testbed’s physical design and operation, virtual environment, as well as their mutual communication is provided. An uncertainty analysis is also performed under manufacturer specified heating and cooling design conditions. This analysis shows that the total load across the WSHP’s demand side heat exchanger, i.e., the sum of its latent and sensible components, can be measured with a relative uncertainty of ± 10.4% and ± 3.6% in cooling and heating mode respectively. The WSHP’s coefficient of performance (COP) can be measured with relative uncertainties of ± 10.4% in cooling mode, and ± 3.7% in heating mode. A preliminary 24-h experimental demonstration is then performed utilizing the DOE prototype small commercial office building model in E+. The simulation takes place in Atlanta, GA on the date of 08/26/15 from 12:00 AM to 11:59 PM using TMY3 weather data. Here, the results from this demonstration show that over the course of this experiment the simulated outputs of zone dry-bulb temperature, zone humidity ratio, and WSHP inlet water temperature can be tracked by testbed emulators up to a root mean squared error (RMSE) of ± 0.27 °C, ± 0.376 g/kg, and ± 0.85 °C respectively. The WSHP’s dynamic behavioral characteristics and performance are also captured, and correspond well with the authors’ previous understanding of heat pump efficiency as a function of evaporator and condenser fluid inlet conditions respectively.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1985

Integrated Application of Active Controls (IAAC) technology to an advanced subsonic transport project: Test act system validation

The primary objective of the Test Active Control Technology (ACT) System laboratory tests was to verify and validate the system concept, hardware, and software. The initial lab tests were open loop hardware tests of the Test ACT System as designed and built. During the course of the testing, minor problems were uncovered and corrected. Major software tests were run. The initial software testing was also open loop. These tests examined pitch control laws, wing load alleviation, signal selection/fault detection (SSFD), and output management. The Test ACT System was modified to interface with the direct drive valve (DDV) modules. The initial testing identified problem areas with DDV nonlinearities, valve friction induced limit cycling, DDV control loop instability, and channel command mismatch. The other DDV issue investigated was the ability to detect and isolate failures. Some simple schemes for failure detection were tested but were not completely satisfactory. The Test ACT System architecture continues to appear promising for ACT/FBW applications in systems that must be immune to worst case generic digital faults, and be able to tolerate two sequential nongeneric faults with no reduction in performance. The challenge in such an implementation would be to keep the analog element sufficiently simple to achieve the necessary reliability.

Source record↗

NASA NTRSDate not supplied

Thermal Protection Materials and Systems at NASA Ames Research Center

Thermal Protection Systems (TPS) are critical for enabling NASA missions involving high-speed atmospheric flight where the entries usually include descending into the atmosphere followed by a trajectory that aims to burn off energy and result in a controlled landing. NASA Ames focuses on qualifying and certifying TPS for current missions, sustaining TPS for future missions, and developing new TPS for upcoming missions where a heritage solution is not viable. More recently there is also a focus on advancing and transferring technologies that can benefit both commercial and government space needs. Developing mature thermal protection systems is a lengthy process involving advanced tools, extensive research, and testing. Design and analysis tools are used to predict aerothermal environments, aid the design of test and flight hardware, and support the testing for the thermal/mechanical response of thermal protection systems. More recently, advances in computational methods help reduce the time and cost of technological advances, aid in optimized material architecture design, and improve material properties and performance. While high-enthalpy testing that simulates the conditions of space flight remains essential for the evaluation and development of TPS materials, computational tools are already showing promise in reducing the need for widespread testing and can help fast-track the design cycle. With the exploration of new destinations EDL instrumentation remains an important element of the heatshield and NASA Ames and partners have developed and delivered instrumentation flight hardware in support of recent Mars missions (MSL and M2020) as well as Artemis Orion. Sensors installed on the heatshield and backshell of spacecraft provide coveted information about the aerodynamic and aerothermal environment during entry. Over the years NASA Ames has brought several reusable and ablative TPS materials to a level of readiness to hand off to missions and the branch continues to serve as a TPS steward for the agency. This presentation will cover current developments in the above areas that have enabled recent missions, and look to future TPS needs for missions such as Ice Giants.

thermal protection materials↗

NASA NTRS1990

M-52 spray booth qualification test

The procedures, performance, and results obtained from the M-52 spray booth qualification test are documented. The test was conducted at Thiokol Corporation, Space Operations, M-52 Inert Parts Preparation facility. The purpose of this testing sequence was to ensure the spray booth would produce flight qualified hardware. The testing sequence was conducted in two series. The first series was conducted under CTP-0142, Revision 1. The second series was conducted in accordance with CTP-0142, Revision 2. The test sequence started with CTP-0142, Revision 1. The series consisted of the contamination removal test and the performance test. The contamination removal test was used to assess the Teflon level in the spray booth. The performance test consisted of painting and Chemloking a forward dome inside the spray booth per flight procedures. During the performance test, two sets of witness panels (case/insulation and steel/epoxy/steel) were prepared and pull tested. The CTP-0142, Revision 2, series of testing consisted of re-testing the steel/epoxy/steel witness panels. The pull tests analysis indicates the results of the tensile tests were comparable to the systems tunnel witness panel database. The exposed panel set and the control panel set average tensile values were above the 1-basis lower limits established on the systems tunnel witness panel database. It is recommended that the M-52 spray booth be qualified for producing flight hardware.

Source record↗