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Global Ecosystem Dynamics Investigation (GEDI) Structural Verification Unit (SVU) Vibration Test

This presentation describes the vibration test campaign of the Structural Verification Unit for the Global Ecosystem Dynamics Investigation (GEDI) mission The Structural Verification Unit test campaign served multiple purposes including the qualification of the instrument primary structure, verification of the structure's stiffness, Aperture Control Mechanism assembly level verification, and validation of the control approach for protoflight instrument vibration testing. Testing included three axes of sine burst, random, and sine vibration excitation. This test sequence required a high number of response instrumentation sensors that included tri-axial accelerometers and tri-axial force gauges. Multiple response limiting methods that included acceleration, force, and moment measurements were used to ensure the safety of the flight hardware. The lessons and specific test details learned on the structural verification unit test campaign will reduce test risks for the upcoming instrument-level vibration tests.

Structural Verification Unit

Modal identification of structures from the responses and random decrement signatures

The theory and application of a method which utilizes the free response of a structure to determine its vibration parameters is described. The time-domain free response is digitized and used in a digital computer program to determine the number of modes excited, the natural frequencies, the damping factors, and the modal vectors. The technique is applied to a complex generalized payload model previously tested using sine sweep method and analyzed by NASTRAN. Ten modes of the payload model are identified. In case free decay response is not readily available, an algorithm is developed to obtain the free responses of a structure from its random responses, due to some unknown or known random input or inputs, using the random decrement technique without changing time correlation between signals. The algorithm is tested using random responses from a generalized payload model and from the space shuttle model.

Brahim, S. R.

Vibration ride comfort criteria

Results are presented for an experimental study directed to derive equal vibration discomfort curves, to determine the influence of vibration masking in order to account for the total discomfort of any random vibration, and to develop a scale of total vibration discomfort in the case of human response to whole-body vertical vibration. Discomfort is referred to as a subjective discomfort associated with the acceleration level of a particular frequency band. It is shown that passenger discomfort to whole-body vibration increases linearly with acceleration level for each frequency. Empirical data provide a mechanism for determining the degree of masking (or summation) of the discomfort of multiple frequency vibration. A scale for the prediction of passenger discomfort is developed.

Dempsey, T. K.

Green Run Modal Test of the NASA Space Launch System Core Stage

The Core Stage of the new NASA Space Launch System (SLS) is a 212-foot tall rocket assembly—consisting primarily of two fuel tanks, an engine section, and four RS-25 rocket engines—capable of sending crew and large payloads to the moon and beyond with 1.6 million pounds of thrust. Currently, the Core Stage is in the B2 Test Stand at Stennis Space Center, undergoing a series of structural and functional tests, designated the Green Run test series. The ultimate goal of Green Run is to verify analytical models and confirm proper subsystem operation of the Core Stage. In January 2020, Green Run testing began with an experimental modal analysis test performed by the Marshal Space Flight Center modal test team. The desired free boundary condition of the Core Stage was achieved by suspending the massive spacecraft from the B2 Test Stand crane. Modal excitation was provided by a pair of 250-lb electro-dynamic shakers for multi-shaker random vibration testing, as well as a 12-pound impact hammer for impact testing. Modal response was measured with 550 accelerometers channels distributed on both the Core Stage and the B2 Test Stand crane. Following one very long night of testing, frequency response functions were calculated from the measured time histories in the target mode frequency range of 2.5 Hz to 15 Hz, and mode shapes, frequencies, and damping values were successfully extracted. The case-study presented in this paper will discuss the SLS Core Stage, the modal test setup and procedure, as well as a brief overview of the test results. Challenges associated with testing such a large, suspended structure in an outdoor environment will be discussed as well.

Green Run

Green Run Modal Test of the NASA Space Launch System Core Stage

The Core Stage of the new NASA Space Launch System (SLS) is a 212-foot-tall rocket assembly—consisting primarily of two cryogenic propellant tanks, an engine section, and four RS-25 rocket engines—that will send crew and large payloads to the moon and beyond for NASA’s Artemis program. Prior to SLS assembly, the Core Stage completed a series of structural and functional tests in the B-2 Test Stand at Stennis Space Center, designated Green Run. The goal of Green Run was to verify analytical models, confirm proper subsystem operation, and test-fire all four RS-25 engines of the Core Stage. In January 2020, Green Run testing began with an experimental modal analysis test, performed by the Marshal Space Flight Center modal test team. A free-boundary test condition of the Core Stage was simulated as close as possible by suspending the massive launch vehicle from the B-2 Test Stand crane. Modal excitation was provided by a pair of 250-lb electro-dynamic shakers for multi-shaker random vibration testing, as well as a 12-pound instrumented hammer for impact testing. Modal response was measured with 550 accelerometer channels distributed on both the Core Stage and the B-2 Test Stand derrick crane. Following one very long day of testing, frequency response functions were calculated from the measured time histories in the target mode frequency range of 5 Hz to 15 Hz, and mode shapes, frequencies, and damping values were successfully estimated. The case-study presented in this paper will discuss Green Run, the SLS Core Stage, the modal test setup and execution, as well as a brief overview of the test results. Challenges associated with testing such a large, suspended structure in an outdoor environment will be discussed as well.

Space Launch System

Investigation of Vibrational Energy Transfer in Connected Structures

The results are reported of an analytical and experimental investigation on the vibrational energy transfer between connected substructures under random excitation. In the analytical area, the basic foundation and assumptions of the statistical energy analysis (SEA) method, a major tool in random response analysis of structures, were examined and reviewed. A new SEA formulation based on the strong coupling condition of the substructures was carried out and presented. Also presented were the results of vibration energy transfer study based on the wave equations applied to connected structures. In the experimental phase, three simple structural models were fabricated and tested. Additional tests were performed on selected substructures which formed parts of the test models. The test results were presented and evaluated against the analytical data.

Hwang, C.

Discomfort criteria for single-axis vibrations

Experimental investigations were conducted to determine the fundamental relationships governing human subjective discomfort response to single-axis vibrations. The axes investigated were vertical, lateral, longitudinal, roll, and pitch, and the vibrations used were both sinusoidal and random in nature. Results of these investigations provided the basis for: (1) development of a scale of passenger discomfort that is common to all axes of vibration; and (2) generation of discomfort criteria for each axis of each axis and for both types of vibration. Furthermore, empirical equations describing discomfort responses within each axis of vibration are included.

Dempsey, T. K.

Vibrations and structureborne noise in space station

Theoretical models were developed capable of predicting structural response and noise transmission to random point mechanical loads. Fiber reinforced composite and aluminum materials were considered. Cylindrical shells and circular plates were taken as typical representatives of structural components for space station habitability modules. Analytical formulations include double wall and single wall constructions. Pressurized and unpressurized models were considered. Parametric studies were conducted to determine the effect on structural response and noise transmission due to fiber orientation, point load location, damping in the core and the main load carrying structure, pressurization, interior acoustic absorption, etc. These analytical models could serve as preliminary tools for assessing noise related problems, for space station applications.

Vaicaitis, R.

Statistical energy analysis of complex structures, phase 2

A method for estimating the structural vibration properties of complex systems in high frequency environments was investigated. The structure analyzed was the Materials Experiment Assembly, (MEA), which is a portion of the OST-2A payload for the space transportation system. Statistical energy analysis (SEA) techniques were used to model the structure and predict the structural element response to acoustic excitation. A comparison of the intial response predictions and measured acoustic test data is presented. The conclusions indicate that: the SEA predicted the response of primary structure to acoustic excitation over a wide range of frequencies; and the contribution of mechanically induced random vibration to the total MEA is not significant.

Trudell, R. W.

On the effect of acoustic coupling on random and harmonic plate vibrations

The effect of acoustic coupling on random and harmonic plate vibrations is studied using two numerical models. In the coupled model, the plate response is obtained by integration of the nonlinear plate equation coupled with the nonlinear Euler equations for the surrounding acoustic fluid. In the uncoupled model, the nonlinear plate equation with an equivalent linear viscous damping term is integrated to obtain the response of the plate subject to the same excitation field. For a low-level, narrow-band excitation, the two models predict the same plate response spectra. As the excitation level is increased, the response power spectrum predicted by the uncoupled model becomes broader and more shifted towards the high frequencies than that obtained by the coupled model. In addition, the difference in response between the coupled and uncoupled models at high frequencies becomes larger. When a high intensity harmonic excitation is used, causing a nonlinear plate response, both models predict the same frequency content of the response. However, the level of the harmonics and subharmonics are higher for the uncoupled model. Comparisons to earlier experimental and numerical results show that acoustic coupling has a significant effect on the plate response at high excitation levels. Its absence in previous models may explain the discrepancy between predicted and measured responses.

Frendi, A.

Effect of acoustic coupling on random and harmonic plate vibrations

The effect of acoustic coupling on random and harmonic plate vibrations is studied using two numerical models. In the coupled model, the plate response is obtained by integration of the nonlinear plate equation coupled with the nonlinear Euler equations for the surrounding acoustic fluid. In the uncoupled model, the nonlinear plate equation with an equivalent linear viscous damping term is integrated to obtain the response of the plate subject to the same excitation field. For a low-level, narrow-band excitation, the two models predict the same plate response spectra. As the excitation level is increased, the response power spectrum predicted by the uncoupled model becomes broader and more shifted towards the high frequencies than that obtained by the coupled model. In addition, the difference in response between the coupled and uncoupled models at high frequencies becomes larger. When a high intensity harmonic excitation is used, causing a nonlinear plate response, both models predict the same frequency content of the response. However, the level of the harmonics and subharmonics are higher for the uncoupled model. Comparisons to earlier experimental and numerical results show that acoustic coupling has a significant effect on the plate response at high excitation levels. Its absence in previous models may explain the discrepancy between predicted and measured responses.

Frendi, Abdelkader

Max Launch Abort System (MLAS) Pad Abort Test Vehicle (PATV) II Attitude Control System (ACS) Integration and Pressurization Subsystem Dynamic Random Vibration Analysis

In order to mitigate catastrophic failures on future generation space vehicles, engineers at the National Aeronautics and Space Administration have begun to integrate a novel crew abort systems that could pull a crew module away in case of an emergency at the launch pad or during ascent. The Max Launch Abort System (MLAS) is a recent test vehicle that was designed as an alternative to the baseline Orion Launch Abort System (LAS) to demonstrate the performance of a "tower-less" LAS configuration under abort conditions. The MLAS II test vehicle will execute a propulsive coast stabilization maneuver during abort to control the vehicles trajectory and thrust. To accomplish this, the spacecraft will integrate an Attitude Control System (ACS) with eight hypergolic monomethyl hydrazine liquid propulsion engines that are capable of operating in a quick pulsing mode. Two main elements of the ACS include a propellant distribution subsystem and a pressurization subsystem to regulate the flow of pressurized gas to the propellant tanks and the engines. The CAD assembly of the Attitude Control System (ACS) was configured and integrated into the Launch Abort Vehicle (LAV) design. A dynamic random vibration analysis was conducted on the Main Propulsion System (MPS) helium pressurization panels to assess the response of the panel and its components under increased gravitational acceleration loads during flight. The results indicated that the panels fundamental and natural frequencies were farther from the maximum Acceleration Spectral Density (ASD) vibrations which were in the range of 150-300 Hz. These values will direct how the components will be packaged in the vehicle to reduce the effects high gravitational loads.

Ekrami, Yasamin

Nonlinear panel response by a Monte Carlo approach

The vibration of clamped and simply supported elastic panels due to subsonic and supersonic turbulent boundary-layer flows is investigated by a Monte Carlo technique. The resulting generalized random forces are simulated numerically from boundary-layer turbulence spectra, and the response analysis is performed in the time domain. The mutual interaction between panel motion and external and/or internal airflow is included. Response studies are performed with respect to rms response, probability structure, peak distribution, threshold crossing and spectral density. The effect on the response statistics of in-plane loading, static pressure differential, and cavity pressure is investigated.

Vaicaitis, R.

Investigation of Multi-Input, Multi-Output (MIMO) Random Control Applied to Direct Field Acoustic Testing

Direct Field Acoustic Testing (DFAT) offers potential cost and time savings over reverberant chamber acoustic testing of spacecraft. The NASA Multi-Purpose Crew Vehicle (MPCV) Program recently directed a series of acoustic tests on Orion structural test articles comparing DFAT and reverberant testing of the same test article with a view to qualifying DFAT for manned space flight vehicles. The verification process compared four parameters noise level compliance with the one third octave test specification, spatial uniformity of the acoustic field, spatial correlation of the acoustic field and vibration response of vehicle structure, including representative solar array panels. While the results of the verification were encouraging, MPCV Loads and Dynamics engaged Quartus Engineering to investigate whether alternative MIMO random control strategies might improve the spatial uniformity and/or the spatial correlation of the DFAT acoustic field. This paper presents the results of acoustic field simulations of the DFAT test and provides a better understanding of how MIMO random control systems originally developed for vibration and structural durability testing can be expected to perform in DFAT testing.

Direct Field

Influence of large deflection and transverse shear on random response of rectangular symmetric composite laminates to acoustic loads

Nonlinear equations of motion of symmetrically laminated anisotropic plates are derived accounting for von Karman strains. The effect of transverse shear is included in the formulation and the rotatory inertia effect is ignored. Using a single-mode Galerkin procedure the nonlinear modal equation is obtained. Direct equivalent linearization is employed. The response of acoustic excitation on moderately thick composite panels is studied. Further, the effects of transverse shear on large deflection vibration of laminates under random excitation are studied. Mean-square deflection and mean-square inplane stresses are obtained for some symmetric graphite-epoxy laminates. Using equilibrium equations and the continuity requirements, the mean-square transverse shear stresses are calculated. The results obtained will be useful in the sonic fatigue design of composite aircraft panels. The analysis is presented in detail for simply supported plate. The analogous equations for a clamped case are given in the appendix.

Mei, Chuh

Modal confidence factor in vibration testing

The theory and applications of a time domain modal test technique are presented. The method uses free decay of random responses from a structure under test to identify its modal characteristics namely, natural frequencies, damping factors, and mode shapes. The method can identify multimodal (highly coupled) systems and modes that have very small contribution in the responses. A method is presented to decrease the effects of high levels of noise in the data and thus improve the accuracy of identified parameters. This is accomplished using an oversized mathematical model. The concept of modal confidence factor (MCF) is developed. The MCF is a number calculated for every identified mode for a structure under test. The MCF varies from 0.000 for a distorted, nonlinear, or noise mode to 100.0 for a pure structural mode. The theory of the MCF is based on the correlation that exits between the modal deflection at a certain station and the modal deflection at the same station delayed in time. The theory and application of the MCF is illustrated by two experiments. The first experiment deals with simulated responses from a two degree of freedom system with 20 percent, 40 percent, and 100 percent noise added. The second experiment was run on a generalized payload model. The free decay response from the payload model contained about 22 percent noise.

Ibrahim, S. R.

Comparison of Nonlinear Random Response Using Equivalent Linearization and Numerical Simulation

A recently developed finite-element-based equivalent linearization approach for the analysis of random vibrations of geometrically nonlinear multiple degree-of-freedom structures is validated. The validation is based on comparisons with results from a finite element based numerical simulation analysis using a numerical integration technique in physical coordinates. In particular, results for the case of a clamped-clamped beam are considered for an extensive load range to establish the limits of validity of the equivalent linearization approach.

Rizzi, Stephen A.