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The advent of triaxial, piezoelectric force gages and the associated signal processing is a precursor to several dynamics testing innovations. This new technology is applicable to spacecraft programs that JPL manages. An application of force measurement is force limiting (when testing spacecraft in random vibration tests). Base-drive and acoustic modal testing is a potential application.
The slosh dynamics of propellant tanks can be represented by an equivalent mass-pendulum-dashpot mechanical model. The parameters of this equivalent model, identified as slosh mechanical model parameters, are slosh frequency, slosh mass, and pendulum hinge point location. They can be obtained by both analysis and testing for discrete fill levels. Anti-slosh baffles are usually needed in propellant tanks to control the movement of the fluid inside the tank. Lateral slosh testing, involving both random excitation testing and free-decay testing, are performed to validate the slosh mechanical model parameters and the damping added to the fluid by the anti-slosh baffles. Traditional modal analysis procedures were used to extract the parameters from the experimental data. Test setup of sub-scale tanks will be described. A comparison between experimental results and analysis will be presented.
NASA is developing a next-generation CO2 removal system, the Four Bed Carbon Dioxide Scrubber (4BCO2), which will use the International Space Station (ISS) as a testbed. A key component of both the existing and the new system is the blower that provides the airflow through the CO2 sorbent beds. To improve performance and reliability, magnetic bearings will be used in lieu of more conventional bearings (e.g. ball bearings or hydrodynamicbearings) to improve resistance to contaminants and enable extensibility with regards to blower speed, pressure rise and mass flow rate. The new blower features a high-efficiency permanent magnet motor, a five-axis, active magnetic bearing system, and a compact controller containing both a variable speed drive and magnetic bearing controller. The blower uses a centrifugal impeller to pull air from the inlet port and drive it through an annular space around the motor and magnetic bearing components to the exhaust port. Technical challenges of the blower and controller development include survival of the blower system under launch random vibration loads, operation in microgravity, packaging under strict size and weight requirements, and successful operation during 4BCO2 operational changeovers. Each serial build of the blower must pass a severe random vibration test to prove it will survive launch conditions. This paper discusses the vibration test requirements and provides details of a simulation performed to estimate the peak backup bearing displacements and loads. Results from the successful random vibration testing of the prototype build are discussed and compared to the simulation.
During random vibration testing of electronic boxes there is often a desire to know the dynamic response of certain internal printed wiring boards (PWBs) for the purpose of monitoring the response of sensitive hardware or for post-test forensic analysis in support of anomaly investigation. Due to restrictions on internally mounted accelerometers for most flight hardware there is usually no means to empirically observe the internal dynamics of the unit, so one must resort to crude and highly uncertain approximations. One common practice is to apply Miles Equation, which does not account for the coupled response of the board in the chassis, resulting in significant over- or under-prediction. This paper explores the application of simple multiple-degree-of-freedom lumped parameter modeling to predict the coupled random vibration response of the PWBs in their fundamental modes of vibration. A simple tool using this approach could be used during or following a random vibration test to interpret vibration test data from a single external chassis measurement to deduce internal board dynamics by means of a rapid correlation analysis. Such a tool might also be useful in early design stages as a supplemental analysis to a more detailed finite element analysis to quickly prototype and analyze the dynamics of various design iterations. After developing the theoretical basis, a lumped parameter modeling approach is applied to an electronic unit for which both external and internal test vibration response measurements are available for direct comparison. Reasonable correlation of the results demonstrates the potential viability of such an approach. Further development of the preliminary approach presented in this paper will involve correlation with detailed finite element models and additional relevant test data.
In order to define random vibration test requirements for Galileo bus-mounted hardware, an extensive vibroacoustics test program was conducted on hardware available from the previous Voyager spacecraft development program. The Galileo test program consisted of acoustic tests on three configurations of the Voyager Dynamic Test Model bus and shaker random vibration tests on two flight-like bus equipment bay assemblies and one dummy equipment bay assembly. The primary goal of the acoustic tests was to define vibration levels at locations on the bus structure representative of inputs to bus equipment bay assemblies and to obtain response data on bus bay subassemblies for correlation with the vibration tests response data. The primary purpose of the vibration tests was to determine if the vibration tests excited subassembly responses at least as severely as the bus acoustic tests.
The Cleanroom software development methodology is designed to take the gamble out of product releases for both suppliers and receivers of the software. The ingredients of this procedure are a life cycle of executable product increments, representative statistical testing, and a standard estimate of the MTTF (Mean Time To Failure) of the product at the time of its release. A statistical approach to software product testing using randomly selected samples of test cases is considered. A statistical model is defined for the certification process which uses the timing data recorded during test. A reasonableness argument for this model is provided that uses previously published data on software product execution. Also included is a derivation of the certification model estimators and a comparison of the proposed least squares technique with the more commonly used maximum likelihood estimators.
The objective of the Mars Micromission program being managed by the Jet Propulsion Laboratory (JPL) for NASA is to develop a common spacecraft that can carry telecommunications equipment and a variety of science payloads for exploration of Mars. The spacecraft will be capable of carrying robot landers and rovers, cameras, probes, balloons, gliders or aircraft, and telecommunications equipment to Mars at much lower cost than recent NASA Mars missions. The lightweight spacecraft (about 220 Kg mass) will be launched in a cooperative venture with CNES as a TWIN auxiliary payload on the Ariane 5 launch vehicle. Two or more Mars Micromission launches are planned for each Mars launch opportunity, which occur every 26 months. The Mars launch window for the first mission is November 1, 2002 through April 2003, which is planned to be a Mars airplane technology demonstration mission to coincide with the 100 year anniversary of the Kittyhawk flight. Several subsequent launches will create a telecommunications network orbiting Mars, which will provide for continuous communication with lenders and rovers on the Martian surface. Dedicated science payload flights to Mars are slated to start in 2005. This new cheaper and faster approach to Mars exploration calls for innovative approaches to the qualification of the Mars Micromission spacecraft for the Ariane 5 launch vibration and acoustic environments. JPL has in recent years implemented new approaches to spacecraft testing that may be effectively applied to the Mars Micromission. These include 1) force limited vibration testing, 2) combined loads, vibration and modal testing, and 3) direct acoustic testing. JPL has performed nearly 200 force limited vibration tests in the past 9 years; several of the tests were on spacecraft and large instruments, including the Cassini and Deep Space One spacecraft. Force limiting, which measures and limits the spacecraft base reaction force using triaxial force gages sandwiched between the spacecraft and the test fixture, alleviates the severe overtest at spacecraft resonances inherent in rigid fixture vibration tests. It has the distinct advantage over response limiting that the method is not dependent on the accuracy of a detailed dynamic model of the spacecraft. Combined loads, vibration, and modal testing were recently performed on the QuikSCAT spacecraft. The combined tests were performed in a single test setup per axis on a vibration shaker, reducing test time by a factor of two or three. Force gages were employed to measure the true c.g. acceleration of the spacecraft for structural loads verification using a sine burst test, to automatically notch random vibration test input accelerations at spacecraft resonances based on predetermined force limits, and to directly measure modal masses in a base drive modal test. In addition to these combined tests on the shaker, the QuikSCAT spacecraft was subjected to a direct field acoustic test by surrounding the spacecraft, still on the vibration shaker, with rock concert type acoustic speakers. Since the spacecraft contractor does not have a reverberant field acoustic test facility, performing a direct field acoustic test -saved the program nearly two weeks schedule time that would have been required for packing / unpacking and shipping of the spacecraft. This paper discusses the rationale behind and advantages of the above test approaches and provides examples of their actual implementation and comparisons to flight data. The applicability of the test approaches to Mars Micromission spacecraft qualification is discussed.
In black-box testing, the tester creates a set of tests to exercise a system under test without regard to the internal structure of the system. Generally, no objective metric is used to measure the adequacy of black-box tests. In recent work, we have proposed three requirements coverage metrics, allowing testers to objectively measure the adequacy of a black-box test suite with respect to a set of requirements formalized as Linear Temporal Logic (LTL) properties. In this report, we evaluate the effectiveness of these coverage metrics with respect to fault finding. Specifically, we conduct an empirical study to investigate two questions: (1) do test suites satisfying a requirements coverage metric provide better fault finding than randomly generated test suites of approximately the same size?, and (2) do test suites satisfying a more rigorous requirements coverage metric provide better fault finding than test suites satisfying a less rigorous requirements coverage metric? Our results indicate (1) only one coverage metric proposed -- Unique First Cause (UFC) coverage -- is sufficiently rigorous to ensure test suites satisfying the metric outperform randomly generated test suites of similar size and (2) that test suites satisfying more rigorous coverage metrics provide better fault finding than test suites satisfying less rigorous coverage metrics.
Ares I Zonal Random vibration environments due to acoustic impingement and combustion processes are develop for liftoff, ascent and reentry. Random Vibration test criteria for Ares I Upper Stage pyrotechnic components are developed by enveloping the applicable zonal environments where each component is located. Random vibration tests will be conducted to assure that these components will survive and function appropriately after exposure to the expected vibration environments. Methodology: Random Vibration test criteria for Ares I Upper Stage pyrotechnic components were desired that would envelope all the applicable environments where each component was located. Applicable Ares I Vehicle drawings and design information needed to be assessed to determine the location(s) for each component on the Ares I Upper Stage. Design and test criteria needed to be developed by plotting and enveloping the applicable environments using Microsoft Excel Spreadsheet Software and documenting them in a report Using Microsoft Word Processing Software. Conclusion: Random vibration liftoff, ascent, and green run design & test criteria for the Upper Stage Pyrotechnic Components were developed by using Microsoft Excel to envelope zonal environments applicable to each component. Results were transferred from Excel into a report using Microsoft Word. After the report is reviewed and edited by my mentor it will be submitted for publication as an attachment to a memorandum. Pyrotechnic component designers will extract criteria from my report for incorporation into the design and test specifications for components. Eventually the hardware will be tested to the environments I developed to assure that the components will survive and function appropriately after exposure to the expected vibration environments.
The Ricor K508N is a rotary Stirling Cryocooler whose predecessor, the K508, has extensive flight heritage. The K508N has significant potential as a low-cost option for CubeSat infrared electro-optical payload applications. This paper will explore the work done by the ATA project on the exported vibration characterization of a set of standard K508N cryocoolers (35 atm) and the implementation and performance comparison of several passive vibration isolation and damping technologies to help mitigate the jitter effect of COTS cryocoolers. Kistler Force dynamometers and accelerometers were used to measure the K508N’s body and cold tip Multicomponent Exported Forces and Torques (EFT). Wire rope and Pyrolytic Graphite Sheet thermal straps are used as vibration isolation technologies. The K508N also underwent sine sweep resonant and peak profile testing as well as random vibration testing to GEVS launch loads in a NanoRacks soft stow configuration.
A comparison of the performance of modern modal data analysis methods on test data from the Voyager Jupiter/Saturn payload is presented. Four different test/data-analysis combinations are compared - multiple-point sine excitation tests, single-point random-excitation tests using two different techniques of manipulating Fourier transform data, and a time-domain method for analyzing random data. Results indicate that all four methods can give comparable results. Of the four, the time-domain approach detects more modes in the test data and, at the same time, shows the greatest promise for reducing the time and cost of modal testing.
The environmental qualification program for the Deep Space 1 spacecraft included a force-limited random vibration test in two axes.
Delivery of Orbital Replacement Units (ORUs) to on-orbit destinations such a the International Space Station (ISS) and the Hubble Space Telescope is an important component of the space program. ORUs are integrated on orbit with space assets to maintain and upgrade functionality. For ORUs comprised of sensitive equipment, the dynamic launch environment drives design and testing requirements, and high frequency random vibrations are generally the cause for failure. Vibration isolation can mitigate the structure-borne vibration environment during launch, and hardware has been developed that can provide a reduced environment for current and future launch environments. Random vibration testing of one ORU to equivalent Space Shuttle launch levels revealed that its qualification and acceptance requirements were exceeded. An isolation system was designed to mitigate the structure-borne launch vibration environment. To protect this ORU, the random vibration levels at 50 Hz must be attenuated by a factor of two and those at higher frequencies even more. Design load factors for Shuttle launch are high, so a metallic load path is needed to maintain strength margins. Isolation system design was performed using a finite element model of the ORU on its carrier with representative disturbance inputs. Iterations on the modelled to an optimized design based on flight proven SoftRide MultiFlex isolators. Component testing has been performed on prototype isolators to validate analytical predictions.
The Centaur LOX boost pump was subjected to both the simulated Titan Centaur proof flight and confidence demonstration vibration test levels. For each test level, both sinusoidal and random vibration tests were conducted along each of the three orthogonal axes of the pump and turbine assembly. In addition to these tests, low frequency longitudinal vibration tests for both levels were conducted. All tests were successfully completed without damage to the boost pump.
Vibration tests were performed to develop and validate the forced limited vibration testing capability at the NASA Langley Research Center. The force limited vibration test technique has been utilized at the Jet Propulsion Laboratory and other NASA centers to provide more realistic vibration test environments for aerospace flight hardware. In standard random vibration tests, the payload is mounted to a rigid fixture and the interface acceleration is controlled to a specified level based on a conservative estimate of the expected flight environment. In force limited vibration tests, both the acceleration and force are controlled at the mounting interface to compensate for differences between the flexible flight mounting and rigid test fixture. This minimizes the over test at the payload natural frequencies and results in more realistic forces being transmitted at the mounting interface. Force and acceleration response data was provided by NASA Goddard Space Flight Center for a test article that was flown in 1998 on a Black Brant sounding rocket. The measured flight interface acceleration data was used as the reference acceleration spectrum. Using this acceleration spectrum, three analytical methods were used to estimate the force limits. Standard random and force limited vibration tests were performed and the results are compared with the flight data.
This is the Performance Verification Report, AMSU-A1 Antenna Drive Subsystem, P/N 1331720-2, S/N 106, for the Integrated Advanced Microwave Sounding Unit-A (AMSU-A). The antenna drive subsystem of the METSAT AMSU-A1, S/N 106, P/N 1331720-2, completed acceptance testing per A-ES Test Procedure AE-26002/lD. The test included: Scan Motion and Jitter, Pulse Load Bus Peak Current and Rise Time, Resolver Reading and Position Error, Gain/ Phase Margin, and Operational Gain Margin. The drive motors and electronic circuitry were also tested at the component level. The drive motor test includes: Starting Torque Test, Motor Commutation Test, Resolver Operation/ No-Load Speed Test, and Random Vibration. The electronic circuitry was tested at the Circuit Card Assembly (CCA) level of production; each test exercised all circuit functions. The transistor assembly was tested during the W3 cable assembly (1356941-1) test.
The preferred method to determine the random uncertainty of variables of interest during wind tunnel tests is by direct analysis of replicate data. However, current information is limited to analysis of a single replicate set condition that does not consider data covariance. This paper provides additional information on considerations for quantifying random uncertainty including the evaluation and correction of replicate data covariance, the selection of replicate set conditions for the test, and the interpolation of random uncertainty at other than replicate set conditions. The analysis and techniques are supported by data from a conventional aircraft configuration test at the Oran Nicks Low-Speed Wind Tunnel and an ASME nozzle flow characterization at the Propulsion Systems Laboratory.
The NASA Glenn Research Center is supporting the development of a Stirling converter with the Department of Energy (DOE, Germantown, Maryland) for an advanced Stirling Radioisotope Power System (SRPS) to provide spacecraft onboard electric power for NASA space science missions. A key technology assessment completed by Glenn and DOE has led to the SRPS being identified as a high-efficiency power source for such deep space missions as the Europa Orbiter and the Solar Probe. In addition, the Stirling system is now being considered for unmanned Mars rovers, especially where mission profiles may exclude the use of photovoltaic power systems, such as exploration at high Martian latitudes or for missions of long duration. The SRPS efficiency of over 20 percent will reduce the required amount of radioisotope by more than a factor of 3 in comparison to current radioisotope thermoelectric generators. This significantly reduces radioisotope cost, radiological inventory, and system cost, and it provides efficient use of scarce radioisotope resources. In support of this technology assessment, Glenn conducted a series of independent evaluations and tests to determine the technology readiness of a 55-We Stirling converter developed by Stirling Technology Company (Kennewick, Washington) and DOE. Key areas evaluated by Glenn included: 1) Radiation tolerance of materials; 2) Random vibration testing of the Stirling converter in Glenn's Structural Dynamics Lab to simulate operation in the launch environment; 3) Electromagnetic interference and compatibility (EMI/EMC) of the converter operating in Glenn's EMI lab; Independent failure modes, effects, and criticality analysis, and life and reliability 4. Independent failure modes, effects, and criticality analysis, and life and reliability assessment; and 5) SRPS cost estimate. The data from these evaluations were presented to NASA Headquarters and the Jet Propulsion Laboratory mission office by a joint industry/Government team consisting of DOE, Glenn, and Lockheed Martin Astronautics. This team concluded that there are no technical reasons that would rule out using the Stirling converter for deep space missions. As a direct result of the successful testing at Glenn, the DOE/Stirling Technology Company 55-We Stirling converter has been baselined for the SRPS. Glenn is now continuing an in-house project to assist in developing the Stirling converter for readiness for space qualification and mission implementation. As part of this effort, the Stirling converter will be further characterized under launch environment random vibration testing, methods to reduce converter EMI will be developed, and an independent performance verification will be completed. Converter life assessment and permanent magnet aging characterization tasks are also underway. Substitute organic materials for the linear alternator and piston bearing coatings for use in a high-radiation environment have been identified and have now been incorporated in Stirling converters built by Stirling Technology Company for Glenn. Electromagnetic and thermal finite element analyses for the alternator are also being conducted.