Search NASA⌕ Search

SEARCH · Search NASA

Results for “hardware testing”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,045 records · Page 58

Electrical Ground Support Equipment for the Sampling Caching System of the Mars 2020 Rover

In this work we describe in detail the architecture, design, testing and operation of the Electrical Ground Support Equipment (EGSE) “Blue Box” used to test and validate the Sampling Caching System (SCS) of the Mars 2020 Perseverance rover. The Blue Box architecture is centered around COTS motor controllers and COTS input-output modules communicating over an EtherCAT bus. A custom, low-level safety subsystem ensures no harm can be done to the flight articles. The modular architecture of the EGSE reduces cost and complexity while expediting assembly time. The Blue Box drives the 19 actuators of the SCS which span the main robotic arm, the corer system, the internal sample handling arm, the sample tube sealing system and the gas dust removal tool; mimicking the Rover Motor Control Assembly (RMCA). Due to the limited availability of RMCA’s, the EGSE enabled and performed the bulk of testing activities for SCS. The majority of the SCS actuators are composed of a 3-phase DC brushless motors, hall sensors for commutation, dual resolvers for output angular measurement, brakes, heaters and platinum thermistors. Additionally, the EGSE read 12 strain gauges forming part of a force torque sensor, and switches used for external positioning references. Over the 3-year span of the V&V campaign for the SCS, over 32 EGSE systems were built, tested and deployed to test venues at JPL and externally. The EGSE tested several families of the SCS subsystem, ranging from engineering units, life test units and two flight units. Test venues that this EGSE supported included lab benches, ultra-clean cleanrooms, ATLO facilities, and thermal vacuum chambers. Together with the test software systems, SSDEV and SSDEV-ECAT, the Blue Box EGSE enabled the team to efficiently test flight hardware and flight software together. We go over the safety features and fault management techniques employed to protect flight hardware. The effects of the long, 50-feet, EGSE harnesses on motor performance, EMI, electrical noise, and motor control performance are explained. Mitigations to these unwanted effects, including shielding strategy and inductance compensation, are summarized. We go over an excerpt of notable anomalies that this EGSE suffered through its operation, along with investigations and resolutions. Lessons learned, areas of improvement as part of future work, and recommendations for future implementations for similar EGSE’s, are shared.

Levine, Dan↗

Assessment of M2020 Terrain Relative Landing Accuracy: Flight Performance vs Predicts

Terrain Relative Navigation (TRN) was a critical enabling Entry, Descent, and Landing (EDL) technology that enabled Mars 2020 mission Perseverance rover to land at Jezero crater. TRN pro-vides real-time, autonomous, map-relative position determination and generates a landing target based on a priori knowledge of hazards. The required performance for TRN was to land within 60m of the selected target. The required 60m was sub-allocated to various error sources in three major categories: targeting error, knowledge error, and control error. The targeting error is the error in selecting an appropriate landing target and the knowledge of the target on the surface. It includes the Lander Vision System (LVS) position localization with respect the ground, the synchronization between the Lander Vision System measurement and the main Navigation filter, and errors associated with the LVS Reference Map and Safe Target Selec-tion (STS). The knowledge error is the contribution of knowledge growth from the synchronization with LVS to touchdown. The control error encompasses how accurately the system could stay on the desired reference trajectory. The TRN error budget uses a combination of analysis, simulation, and hardware test-ing results to bound the various error contributions obtained during the verification and validation process. This paper first presents a description the TRN system, focusing on the architecture of LVS and STS. The paper then gives detailed overview of the TRN error budget, with a description of the major error contribu-tions in each of the three categories. Next, the paper gives the results for three versions of the error budget, pre-launch, in-flight pre-landing, and post-landing. The paper compares the pre-flight analysis, the pre-landing analysis using in-flight data during cruise, to the post-landing analysis of the TRN performance. Pre-landing analysis best estimate of the landing performance was 33m, compared to the 60m require-ment. Post-landing analysis estimated a landing accuracy of 8.53m or better, much better than the 33m pre-landing estimate. The actual post-landing imagery calculated the distance of the rover to the targeted location to be 5m. The post-landing analysis closely bounds the image-based assessment of landing accu-racy, indicating the success of the error budget architecture in bounding the landing accuracy, as well as the fidelity of the simulations used to model and predict performance.

Chen, Allen↗

Development of an Extended Reality (XR) Tool for Earth Science Visualization

In this presentation, we will discuss our work in adapting the NASA open source XR software, the Mixed Reality Exploration Toolkit (MRET), to an earth science domain. MRET is a NASA open source XR software for rapidly building extended reality (XR) environments for NASA domain problems, e.g., pulling in CAD models of thermal vac chamber and Roman Space Telescope to do fit checks. Primarily used for hardware integration & test, we have been adapting and extending MRET for science problems. Traditionally, scientists view and analyze the result of calculated or measured observables with static 1-D, 2-D or 3-D plots. It can be difficult to identify, track and understand the evolution of key features due to poor viewing angles and the nature of flat computer screens. Additionally, numerical models, such as the NASA GEOS climate model, are almost exclusively formulated and analyzed on Eulerian grids with points fixed in space and time. However, atmospheric phenomena such as convective clouds, hurricanes and wildfire smoke plumes move with the 3-D flow field, and it is often difficult and unnatural to understand these phenomena in an Eulerian reference frame as opposed to the Lagrangian reference frame in which nature operates. As part of an Earth Science Technology Office (ESTO) proposal, we have been adapting MRET to be a scientific exploration and analysis XR tool with integrated Lagrangian Dynamics (LD) for the Goddard Earth Observing System (GEOS) numerical weather prediction model. We believe this will help scientists identify, track, and understand the evolution of Earth Science phenomena. This presentation will discuss current results in our work in developing this XR tool for Earth Science.

Thomas G Grubb↗

Maneuverable Automated Tethered Space Tug Simulator

This TIP will develop autonomous capabilities for the space tugs in the Flat Floor Robotics Laboratory (FFRL) for use in support of In-Space Servicing, Assembly, and Manufacturing (ISAM) and future vehicles in the FFRL. The space tugs would be housed on larger spacecraft, such as ISS or Gateway, and deployed for various ISAM activities. When these activities are complete, the space tug can be reeled back to its host spacecraft.

Flat Floor Robotics Lab↗

Development of an Extended Reality (XR) Tool for Earth Science Visualization

In this presentation, we will discuss our work in adapting the NASA open source XR software, the Mixed Reality Exploration Toolkit (MRET), to an earth science domain. MRET is a NASA open source XR software for rapidly building extended reality (XR) environments for NASA domain problems, e.g., pulling in CAD models of thermal vac chamber and Roman Space Telescope to do fit checks. Primarily used for hardware integration & test, we have been adapting and extending MRET for science problems. Traditionally, scientists view and analyze the result of calculated or measured observables with static 1-D, 2-D or 3-D plots. It can be difficult to identify, track and understand the evolution of key features due to poor viewing angles and the nature of flat computer screens. Additionally, numerical models, such as the NASA GEOS climate model, are almost exclusively formulated and analyzed on Eulerian grids with points fixed in space and time. However, atmospheric phenomena such as convective clouds, hurricanes and wildfire smoke plumes move with the 3-D flow field, and it is often difficult and unnatural to understand these phenomena in an Eulerian reference frame as opposed to the Lagrangian reference frame in which nature operates. As part of an Earth Science Technology Office (ESTO) proposal, we have been adapting MRET to be a scientific exploration and analysis XR tool with integrated Lagrangian Dynamics (LD) for the Goddard Earth Observing System (GEOS) numerical weather prediction model. We believe this will help scientists identify, track, and understand the evolution of Earth Science phenomena. This presentation will discuss current results in our work in developing this XR tool for Earth Science.

Thomas Grubb↗

MSFC Thermal Testing Lessons Learned Course. Section 3: Lessons Learned from Protoflight StarBurst Instrument Thermal Vacuum Test

MSFC thermal engineers will be presenting lessons learned while preparing and conducting thermal tests. This course will cover practical real world examples of thermal chamber and vacuum chamber testing from engineering development units to system level testing on flight hardware. Special topics include large scale testing preparation, requirement tailoring from parent documents, and cryogenic development testing.

thermal discipline↗

Four Design Demonstration Elments (DDEs) to be irradiated in the Advanced Test Reactor (ATR) and the Belgian Reactor 2 (BR2)

The U.S. High Performance Research Reactor Conversion fuel qualification team is focused on developing and qualifying plate type uranium-molybdenum (U-Mo) monolithic and uranium silicide (U3Si4) fuel. Several irradiations of mini-plates and full-size plate irradiations will demonstrate the fuel’s behavior. Along with qualifying fuel, larger tests are planned to support licensing fuel elements. These tests are referred to as DDEs. As a result of a scoping study performed in 2018, a decision was made to irradiate two DDEs in ATR at the Idaho National Laboratory (INL) and two other DDEs in BR2 in Belgium. The objective is to demonstrate successful irradiation of each DDE to support the licensing submittal of that specific reactor. Neutronics analysis is being performed to match the power density distribution of the represented elements. Test train hardware design are being done to ensure all the target conditions are being met for the two DDEs to be irradiated.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Exploration Extravehicular Mobility Unit (xEMU) Lunar Boot Chamber B Thermal Vacuum Testing Results

NASA’s Exploration Extravehicular Mobility Unit (xEMU) is the government reference next-generation spacesuit design and is engineered to protect astronauts from extreme lunar environmental temperatures. To evaluate the xEMU hardware thermal requirements, the xEMU Testing Team invented, designed, and executed a dual-suit, uncrewed thermal vacuum (TVAC) test at Johnson Space Center’s (JSC) Chamber B. This paper details the test methodology, hardware setup, and results from the xEMU lunar boots. Eleven unique thermal profiles were tested including both cold and hot environmental cases over the course of five continuous days of testing. This paper will address only the cold environment testing results. The radiative thermal environment was controlled through exposure to liquid-nitrogen shrouds on the chamber walls and through a heater cage surrounding the boots. Notably, the xEMU boots also contacted the liquid-nitrogen chilled floor inside of Chamber B, which provided a conduction pathway to simulate the thermal effects of the lunar surface. Test hardware was developed to extend the water tubing from the Liquid Cooling Ventilation Garment (LCVG) into the boots to set the internal thermal boundary nominally provided by the astronaut’s foot. Thirty-three temperature sensors were used to collect data in critical locations in the xEMU boot assembly as well as for calorimetry to determine heat flux to and from the boots. This paper will document the testing results and provide a high-level interpretation of the testing results. To conclude, this paper will address possible forward work and knowledge gaps present in lunar boot thermal performance and testing.

xEMU↗

Building a Simplistic Automatic Extruder: Instrument Development Opportunities for the Laboratory

This work presents an automatic extruder as a research experience for undergraduate students. The system offers a user-friendly approach to preparing vesicles, such as liposomes or polymersomes, with a defined size and polydispersity properties crucial for research in biology and macromolecules. It comprises two syringe pumps connected by a membrane filter. The setup is controlled by software. Compared to manual extrusion, this automated system provides advantages, such as precisely controlled variables. The project describes a tool to enhance undergraduate learning in science and engineering laboratories. Building an automatic extruder serves as a simplified model of a complex industrial process. It offers a clear advantage: automating a well-understood manual extrusion process. To make this project accessible, it is broken down into three manageable tasks: software development, hardware assembly, and testing procedures. This breakdown describes the software created, the hardware components used, and the testing procedures conducted for this project. All project data, including software code, testing data, and procedures, are freely available online. This allows undergraduate students to not only begin their own projects but also contribute to this educational instrument’s ongoing development.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

A method of hardware qualification for flight by analyses, similarity and integrated testing

The results are described of a study on four pieces of flight hardware from the Saturn 1U and S-4B stages to determine whether the objectives of the formal qualification tests on that hardware could have been obtained within that program by methods other than performing the qualification tests. These methods include qualification by analyses, similarity and integrated testing, i.e., distribution of the objectives among the other tests in the program. It was found that it is feasible to delete the requirements for formal qualification testing provided that it is accomplished early in the program to allow adequate planning for accomplishing the qualification objectives by other means. Additionally, a scorekeeping system was defined that is simple, straightforward, easy to implement. This scorekeeping system provides complete visibility of equivalent qualification status at any point during the program. A set of groundrules for implementing this study was established as a result of findings on the specific items of hardware studied.

Andriulli, J. B.↗

Motor Qualification for Long-Duration Mars Missions

Qualification of motors for deep space under extreme thermal environments to be encountered during the Mars Science Laboratory (MSL) mission is required to verify the reliability and validate mission assurance requirements. The motor assembly must survive all ground operations, plus the nominal 670 Martian-day (or sol) mission that includes summer and winter seasons of the Mars environment. The motor assembly was tested and characterized under extreme temperature conditions with reference to hardware requirements. The motor assembly has been proved to be remarkably robust and displayed no sign of degradation due to the 3 X (three times per JPL design principles) thermal environmental exposure to the punishing Mars surface operations cycles. The motor characteristics obtained before, during, and post-test comparisons for the surface operations cycles are within measurement error of one another. The motors withstood/survived 2,010 extreme temperature cycles with a Delta T of 190 C deep temperature cycles, representing three times the expected thermal cycling exposure during the MSL surface operations. The qualification test hardware elements (A200 motor assembly, encoders, and resolver) have not shown any signs of degradation due to the PQV (Package Qualification and Verification) testing. The test hardware has demonstrated sufficient life to survive the deep thermal cycles associated with MSL mission surface operations for three lives.

Ramesham, Rajeshuni↗

Microreactor Automated Control System Test Bed Digital Architecture for Real-Time, Hardware-in-the-Loop Simulation

This work describes progress made towards the development of a real-time hardware-in-the-loop (HIL) test bed for non-nuclear testing of microreactor control schemes and failure modes. Non-nuclear testing is a crucial step in developing robust control algorithms for managing microreactor dynamics. The creation of an HIL simulation harnesses the realistic dynamics of physical analogue systems while additionally considering the challenges of variable communication delay. This collaborative effort between Oak Ridge National Laboratory and Idaho National Laboratory has resulted in a LabVIEW-based gRPC communication protocol which couples a TRANSFORM Modelica simulation of nuclear components to the ViBRANT physical hardware for realistic feedback and visual representation of control action in real time. A modular python client structure is developed to manage FMU-based Modelica simulation and real-time gRPC communication. HIL testing suggests that the modeled reactor with natural convection molten salt loop coolant configuration responds well to PID control of drum positioning for modulation of reactor core power, however, future efforts will be made to explore the added thermal inertial delay of system level control and downstream demand changes. Development of this platform with a generalized methodology provides a foundation for exploring a variety of reactor configurations and failure modes in rapid order to provide insight into the most effective avenues of study for further research and development.

McConnell, Jono [ORNL] (ORCID:0000000238984741)↗

GRC Ground Support Facilities

The ISS Program is conducting an "ISS Research Academy' at JSC the first week of August 2010. This Academy will be a tutorial for new Users of the International Space Station, focused primarily on the new ISS National Laboratory and its members including Non-Profit Organizations, other government agencies and commercial users. Presentations on the on-orbit research facilities accommodations and capabilities will be made, as well as ground based hardware development, integration and test facilities and capabilities. This presentation describes the GRC Hardware development, test and laboratory facilities.

SaintOnge, Thomas H.↗

Determining Temperature Differential to Prevent Hardware Cross-Contamination in a Vacuum Chamber

When contamination-sensitive hardware must be tested in a thermal vacuum chamber, cross-contamination from other hardware present in the chamber, or residue from previous tests, becomes a concern. Typical mitigation strategies involve maintaining the temperature of the critical item above that of other hardware elements at the end of the test. A formula for relating the pumping speed of a chamber, the surface area of contamination sources, and the temperatures of the chamber, source, and contamination-sensitive items has been developed. The formula allows the determination of a temperature threshold about which contamination will not condense on the sensitive items. It defines a parameter alpha that is the fraction given by (contaminant source area)/[chamber pumping speed (time under vacuum) 0.5]. If this parameter is less than 10(exp -6), cross-contamination from common spacecraft material will not occur when the sensitive hardware is at the same temperature as the source of contamination (The chamber is isothermal within 5 C.). Knowing when it becomes safe to have the hardware isothermal permits faster and easier thermal transitions when compared with maintaining an arbitrary temperature differential between parts. Furthermore, the standard temperature differential may not be adequate under some conditions (alpha>10(exp -4)).

Hughes, David↗

Field Demonstration of The Krauklis Seismic Wave In A Novel Mva Method For Geologic CO 2 Storage

The Energy & Environmental Research Center (EERC) conducted a feasibility study of a new, low-impact geophysics monitoring method designed to incrementally track the saturation front of CO 2 injected into a reservoir. The method leverages a new way of transmitting energy from the surface to the reservoir and employs a new subsurface signal called the Krauklis wave (K-wave) and other guided waves for seismic monitoring. The EERC partnered with Seismos, Inc., the company that holds the exclusive technology license for this method, to advance development of K-wave technology, and Denbury Onshore, LLC, to field-test the system. The system was field-tested at Denbury’s Bell Creek oil field, currently undergoing CO 2 -based enhanced oil recovery (EOR) in southeastern Montana. The K-wave system uses a wellhead-mounted source to propagate energy down the wellbore in the form of a tube wave and through the well perforations into the reservoir. Part of the energy transmitted through the perforations into the reservoir converts to slow moving K-waves and/or other guided waves that are expected to propagate through the formation to neighboring wells. The propagated signal would induce tube waves in the neighboring wells that return to the surface to be recorded with a wellhead-mounted receiver. The propagation time of the signal is directly affected by the presence of CO 2 between the wells, so the difference in transit time of the returning signal between pre- and postinjection data sets could be used to help define the lateral extent of a CO 2 saturation front. Objectives of the study were to demonstrate, validate, and evaluate the K-wave method’s ability to monitor the morphology of injected CO 2 and estimate saturation distribution. Results from the demonstration were to be compared to conventional 4-D surface seismic methods, dynamic reservoir simulations, and CO 2 breakthrough data to validate the technology and provide useful information that may result in improvements. Prior to mobilizing for the full-scale K-wave baseline survey, a field test was conducted to better understand wellhead hardware configurations and test the response from the Bell Creek reservoir using three wells. Useful operational information resulted but signal from the first-generation gas release/gas injection source was not recorded in neighboring wells. After the initial field test, numerical modeling of the K-wave method was initiated using parameters specific to the Bell Creek Field. Modeling results indicated that the fundamental concepts behind the K-wave method exhibited problems and revealed a significantly greater attenuation of the signal at the wellbore perforations than expected, totaling on the order of 10-8 from source well to receiver well over a 400-m well spacing. Modeling also showed that greater source frequency bandwidth was needed to produce guided waves within a 30-foot-thick reservoir layer such as that at Bell Creek and that reservoir layer seismic velocity would need to be slower than the velocities of the bounding layers in order to act as a wave guide opposite to what exists at Bell Creek. Modeling results prompted a second field test with a stronger, second-generation displacement source developed in the interim. Concurrent with the second field test, a 3-D seismic survey was acquired to serve as a baseline for project validation and to serve as a monitor data set for the portion of the project area where CO 2 injection had already commenced. The new source was tested using a four-well geometry and failed to produce a detectable signal, which appeared to confirm modeling results and indicated that the Bell Creek Field is not an ideal site for the K-wave test. It was concluded that a source with sufficient strength and bandwidth could not be built to overcome the factors discovered by the modeling within a reasonable amount of time. Several other sites undergoing CO 2 -based EOR were also evaluated; however, none of these sites was amenable because of geology, limitations of source and receiver hardware, or the advanced state of the CO 2 flood. In addition, two other configurations of the source and receiver layout were considered; however, these design modifications either changed the scope of the project or did not meet the goals of the Carbon Storage Program. In consultation with the U.S. Department of Energy (DOE) Project Manager and Technology Manager, a no-go decision was invoked to forego additional expenditures as the technology would not meet current project objectives. Project activities to date have moved the technology forward by developing modeling equations that can be applied elsewhere, advanced the state of wellhead sensors and sources, and spurred improvements to field operations. The 3-D seismic survey in the project area and the dynamic reservoir simulations done as part of this study have provided value for ongoing and future synergistic activities at Bell Creek related to DOE carbon storage goals.

54 ENVIRONMENTAL SCIENCES↗

Thomas Leps Internship Abstract

An optical navigation system is being flown as the backup system to the primary Deep Space Network telemetry for navigation and guidance purposes on Orion. This is required to ensure Orion can recover from a loss of communication, which would simultaneously cause a loss of DSN telemetry. Images taken of the Moon and Earth are used to give range and position information to the navigation computer for trajectory calculations and maneuver execution. To get telemetry data from these images, the size and location of the moon need to be calculated with high accuracy and precision. The reentry envelope for the Orion EM-1 mission requires the centroid and radius of the moon images to be determined within 1/3 of a pixel 3 sigma. In order to ensure this accuracy and precision can be attained, I was tasked with building precise dot grid images for camera calibration as well as building a hardware in the loop test stand for flight software and hardware proofing. To calibrate the Op-Nav camera a dot grid is imaged with the camera, the error between the image dot location and the actual dot location can be used to build a distortion map of the camera and lens system so that images can be fixed to display truth locations. To build the dot grid images I used the Electro Optics Lab optical bench Bright Object Simulator System, and gimbal. The gimbal was slewed to a series of elevations and azimuths. An image of the collimated single point light source was then taken at each position. After a series of 99 images were taken at different locations the single light spots were extracted from each image and added to a composite image containing all 99 points. During the development of these grids it was noticed that an intermittent error in the artificial "star" locations occurred. Prior to the summer this error was attributed to the gimbal having glitches in it's pointing direction and was going to be replaced, however after further examining the issue I determined it to be a software issue. I have since narrowed the likely source of the error down to a Software Development Kit released by the camera supplier PixeLink. I have since developed a workaround in order to build star grids for calibration until the software bug can be isolated and fixed. I was also tasked with building a Hardware in the Loop test stand in order to test the full Op-Nav system. A 4k screen displays simulated Lunar and Terrestrial images from a possible Orion trajectory. These images are then projected through a collimator and then captured with an Op-Nav camera controlled by an Intel NUC computer running flight software. The flight software then analyzes the images to determine attitude and position, this data is then reconstructed into a trajectory and matched to the simulated trajectory in order to determine the accuracy of the attitude and position estimates. In order for the system to work it needs to be precisely and accurately aligned. I developed an alignment procedure that allows the screen, collimator and camera to be squared, centered and collinear with each other within a micron spatially and 5 arcseconds in rotation. I also designed a rigid mount for the screen that was machined on site in Building 10 by another intern. While I was working in the EOL we received a $500k Orion startracker for alignment procedure testing. Due to my prior experience in electronics development, as an ancillary duty, I was tasked with building the cables required to operate and power the startracker. If any errors are made building these cables the startracker would be destroyed, I was honored that the director of the lab entrusted such a critical component with me. This internship has cemented my view on public space exploration. I always preferred public sector to privatization because, as a scientist, the most interesting aspects of space for me are not necessarily the most profitable. I was concerned that the public sector was faltering however, and that in order to improve human space exploration I would be forced into private sector. I now know that, at least at JSC, human spaceflight is still progressing, and exciting work is still being done. I am now actively seeking employment at JSC after I complete my Ph.D and have met with my branch chiefs and mentor to discuss transitioning to a grad Co-op position.

Leps, Thomas↗

Validation of Test Methods for Air Leak Rate Verification of Spaceflight Hardware

As deep space exploration continues to be the goal of NASAs human spaceflight program, verification of the performance of spaceflight hardware becomes increasingly critical. Suitable test methods for verifying the leak rate of sealing systems are identified in program qualification testing requirements. One acceptable method for verifying the air leak rate of gas pressure seals is the tracer gas leak detector method. In this method, a tracer gas (commonly helium) leaks past the test seal and is transported to the leak detector where the leak rate is quantified. To predict the air leak rate, a conversion factor of helium-to-air is applied depending on the magnitude of the helium flow rate. The conversion factor is based on either the molecular mass ratio or the ratio of the dynamic viscosities. The current work was aimed at validating this approach for permeation-level leak rates using a series of tests with a silicone elastomer O-ring. An established pressure decay method with constant differential pressure was used to evaluate both the air and helium leak rates of the O-ring under similar temperature and pressure conditions. The results from the pressure decay tests showed, for the elastomer O-ring, that neither the molecular flow nor the viscous flow helium-to-air conversion factors were applicable. Leak rate tests were also performed using nitrogen and argon as the test gas. Molecular mass and viscosity based helium-to-test gas conversion factors were applied, but did not correctly predict the measured leak rates of either gas. To further this study, the effect of pressure boundary conditions was investigated. Often, pressure decay leak rate tests are performed at a differential pressure of 101.3 kPa with atmospheric pressure on the downstream side of the test seal. In space applications, the differential pressure is similar, but with vacuum as the downstream pressure. The same O-ring was tested at four unique differential pressures ranging from 34.5 to 137.9 kPa. Up to six combinations of upstream and downstream pressures for each differential pressure were compared. For a given differential pressure, the various combinations of upstream and downstream dry air pressures did not significantly affect the leak rate. As expected, the leak rate of the O-ring increased with increasing differential pressure. The results suggested that the current leak test pressure conditions, used to verify spacecraft sealing systems with elastomer seals, produce accurate values even though the boundary conditions do not model the space application.

helium leak detector↗

Electromechanical propellant control system actuator

New control mechanism technologies are currently being sought to provide alternatives to hydraulic actuation systems. The Propulsion Laboratory at Marshall Space Flight Center (MSFC) is involved in the development of electromechanical actuators (EMA's) for this purpose. Through this effort, an in-house designed electromechanical propellant valve actuator has been assembled and is presently being evaluated. This evaluation will allow performance comparisons between EMA and hydraulics systems. The in-house design consists of the following hardware: a three-phase brushless motor, a harmonic drive, and an output spline which will mate with current Space Shuttle Main Engine (SSME) propellant control valves. A resolver and associated electronics supply position feedback for the EMA. System control is provided by a solid-state electronic controller and power supply. Frequency response testing has been performed with further testing planned as hardware and test facilities become available.

Myers, W. Neill↗