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NASA NTRS1996

STS-74 Space Shuttle Mission Report

The STS-74 Space Shuttle Program Mission Report summarizes the Payload activities as well as the Orbiter, External Tank (ET), Solid Rocket Booster (SRB), Reusable Solid Rocket Motor (RSRM), and the Space Shuttle main engine (SSME) systems performance during the seventy-third flight of the Space Shuttle Program, the forty-eighth flight since the return-to-flight, and the fifteenth flight of the Orbiter Atlantis (OV-104). In addition to the Orbiter, the flight vehicle consisted of an ET that was designated ET-74; three Phase 11 SSME's that were designated as serial numbers 2012, 2026, and 2032 in positions 1, 2, and 3, respectively; and two SRB's that were designated BI-076. The RSRM's, designated RSRM-51, were installed in each SRB and the individual RSRM's were designated as 360TO51 A for the left SRB, and 360TO51 B for the right SRB. The primary objectives of this flight were to rendezvous and dock with the Mir Space Station and perform life sciences investigations. The Russian Docking Module (DM) was berthed onto the Orbiter Docking System (ODS) using the Remote Manipulator System (RMS), and the Orbiter docked to the Mir with the DM. When separating from the Mir, the Orbiter undocked, leaving the DM attached to the Mir. The two solar arrays, mounted on the DM, were delivered for future Russian installation to the Mir. The secondary objectives of the flight were to perform the operations necessary to fulfill the requirements of the GLO experiment (GLO-4)/Photogrammetric Appendage Structural Dynamics Experiment Payload (PASDE) (GPP), the IMAX Cargo Bay Camera (ICBC), and the Shuttle Amateur Radio Experiment-2 (SAREX-2). Appendix A lists the sources of data, both formal and informal, that were used to prepare this report. Appendix B provides the definition of acronyms and abbreviations used throughout the report. All times during the flight are given in Greenwich mean time (GMT)) and mission elapsed time (MET).

Fricke, Robert W., Jr.↗
NASA NTRS2002

University Nanosatellite Program ION-F Constellation

The Space Engineering program at Utah State University has developed a small satellite, known as USUSat, under funding from AFOSR, AFRL, NASA and Utah State University's Space Dynamics Laboratory. This satellite was designed and significantly manufactured by students in the Mechanical and Aerospace Engineering and the Electrical and Computer Engineering Departments within the College of Engineering. USUSat is one of three spacecraft being designed for the Ionospheric Observation Nanosatellite Formation (ION- F). This formation comprises three 15 kg. spacecraft designed and built in cooperation by Utah State University, University of Washington, and Virginia Polytechnic Institute. The ION-F satellites are being designed and built by students at the three universities, with close coordination to insure compatibility for launch, deployment, and the formation flying mission. The JON-F mission is part of the U.S. Air Force Research Laboratory (AFRL) University Nanosatellite Program, which provides technology development and demonstrations for the TechSat2l Program. The University Nanosatellite Program involves 10 universities building nanosatellites for a launch in 2004 on two separate space shuttle missions. Additional support for the formation flying demonstration has been provided by NASA's Goddard Space Flight Center.

NANOSATS (NANOSATELLITES)↗
NASA NTRS2008

Technical Progress on the Ares I-X Flight Test

Ares I-X will be NASA's first test flight for a new human-rated launch vehicle since 1981, and the team is well on its way toward completing the vehicle's design and hardware fabrication for an April 2009 launch. This uncrewed suborbital development test flight gives NASA its first opportunities to: gather critical data about the flight dynamics of the integrated launch vehicle; understand how to control its roll during flight; better characterize the stage separation environments during future flight; and demonstrate the first stage recovery system. The Ares I-X Flight Test Vehicle (FTV) incorporates a mix of flight and mockup hardware. It is powered by a four-segment solid rocket booster, and will be modified to include a fifth, spacer segment; the upper stage, Orion crew exploration vehicle, and launch abort system are simulator hardware to make the FTV aerodynamically similar to the same size, shape, and weight of Ares I. The Ares IX first stage includes an existing Shuttle solid rocket motor and thrust vector control system controlled by an Ascent Thrust Vector Controller (ATVC) designed and built by Honeywell International. The avionics system will be tested in a dedicated System Integration Laboratory located at Lockheed Martin Space Systems (LMSS) in Denver, Colorado. The Upper Stage Simulator (USS) is made up of cylindrical segments that will be stacked and integrated at Kennedy Space Center (KSC) for launch. Glenn Research Center is already building these segments, along with their internal access structures. The active Roll Control System (RoCS) includes two thruster units harvested from Peacekeeper missiles. Duty cycle testing for RoCS was conducted, and fuel tanking and detanking tests will occur at KSC in early 2008. This important flight will provide valuable experience for the ground operations team in integrating, stacking, and launching Ares I. Data from Ares I-X will ensure the safety and reliability of America's newest launch vehicle.

Davis, S.R.↗
NASA NTRS1974

Development of technology for modeling of a 1/8-scale dynamic model of the shuttle Solid Rocket Booster (SRB)

A NASTRAN analysis of the solid rocket booster (SRB) substructure of the space shuttle 1/8-scale structural dynamics model. The NASTRAN finite element modeling capability was first used to formulate a model of a cylinder 10 in. radius by a 200 in. length to investigate the accuracy and adequacy of the proposed grid point spacing. Results were compared with a shell analysis and demonstrated relatively accurate results for NASTRAN for the lower modes, which were of primary interest. A finite element model of the full SRB was then formed using CQUAD2 plate elements containing membrane and bending stiffness and CBAR offset bar elements to represent the longerons and frames. Three layers of three-dimensional CHEXAI elements were used to model the propellant. This model, consisting of 4000 degrees of freedom (DOF) initially, was reduced to 176 DOF using Guyan reduction. The model was then submitted for complex Eigenvalue analysis. After experiencing considerable difficulty with attempts to run the complete model, it was split into two substructres. These were run separately and combined into a single 116 degree of freedom A set which was successfully run. Results are reported.

Levy, A.↗
NASA NTRS1990

Prediction of the Thrust Performance and the Flowfield of Liquid Rocket Engines

In an effort to improve the current solutions in the design and analysis of liquid propulsive engines, a computational fluid dynamics (CFD) model capable of calculating the reacting flows from the combustion chamber, through the nozzle to the external plume, was developed. The Space Shuttle Main Engine (SSME) fired at sea level, was investigated as a sample case. The CFD model, FDNS, is a pressure based, non-staggered grid, viscous/inviscid, ideal gas/real gas, reactive code. An adaptive upwinding differencing scheme is employed for the spatial discretization. The upwind scheme is based on fourth order central differencing with fourth order damping for smooth regions, and second order central differencing with second order damping for shock capturing. It is equipped with a CHMQGM equilibrium chemistry algorithm and a PARASOL finite rate chemistry algorithm using the point implicit method. The computed flow results and performance compared well with those of other standard codes and engine hot fire test data. In addition, the transient nozzle flowfield calculation was also performed to demonstrate the ability of FDNS in capturing the flow separation during the startup process.

Wang, T.-S.↗
NASA NTRS2006

Marshall Space Flight Center Autumn 2005

The East Test Area at Marshall Space Flight Center has five major test stands, each of which has two or more test positions, not counting the SSME and RD-180 engine test facilities in the West Test Area. These research and development facilities are capable of testing high pressure pumps, both fuel and oxidizer, injectors, chambers and sea-level engine assemblies, as well as simulating deep space environments in the 12, 15 and 20 foot vacuum chambers. Liquid propellant capabilities are high pressure hydrogen (liquid and gas), methane (liquid and gas), and RP-1 and high pressure LOX. Solid propellant capability includes thrust measurement and firing capability up to 1/6 scale Shuttle SRB segment. In the past six months MSFC supported multiple space access and exploration programs in the previous six months. Major programs were Space Exploration, Shuttle External Tank research, Reusable Solid Rocket Motor (RSRM) development, as well as research programs for NASA and other customers. At Test Stand 115 monopropellant ignition testing was conducted on one position. At the second position multiple ignition/variable burn time cycles were conducted on Vacuum Plasma Spatter (VPS) coated injectors. Each injector received fifty cycles; the propellants were LOX Hydrogen and the ignition source was TEA. Following completion of the monopropellant test series the stand was reconfigured to support ignition testing on a LOX Methane injector system. At TS 116 a thrust stand used to test Booster Separation Motors from the Shuttle SRB system was disassembled and moved from Chemical Systems Division s Coyote Canyon plant to MSFC. The stand was reassembled and readied for BSM testing. Also, a series of tests was run on a Pratt & Whitney Rocketdyne Low Element Density (LED) injector engine. The propellants for this engine are LOX and LH2. At TS 300 the 20 foot vacuum chamber was configured to support hydrogen testing in the Multipurpose Hydrogen Test Bed (MHTB) test article. This testing, which went 24/7 for fourteen consecutive days, demonstrated long duration storage methods intended to minimize losses of propellant in support of the Space Exploration Initiative. The facility is being converted to support similar research using liquid methane. The 12 foot chamber at TS 300 was used to create ascent profiles (both heat and altitude effects) for foam panel testing in support of the Shuttle External Tank program. At TS 500, one position was in build-up to support ATK Thiokol research into the gas dynamics associated with high pressure flow across the propellant joint in segmented solid rocket motors. The testing involves flowing high pressure gas through a 24 motor case. Initial tests will be conducted with simulated aluminum grain, followed by tests using actual propellant. The second position at TS 500 has been in build-up for testing a LOX methane thruster manufactured by KT Engineering. At the Solid Propulsion Test Area (SPTA), the first dual segment 24 solid rocket motor was fired for ATK Thiokol in support of the RSRM program. A new axial thrust measurement stand was designed and fabricated for this testing. Real Time Radiography (RTR) will be deployed to examine nozzle erosion on the next dual segment motor.

Allen, Mike↗
NASA NTRS1974

Development of technology for fluid-structure interaction modeling of a 1/8-scale dynamic model of shuttle External Tank (ET). Volume i: Technical report

A NASTRAN analysis of the external tank (ET) substructure of the 1/8-scale space shuttle structural dynamics model is described. The NASTRAN hydroelastic procedures were used to form a model of the liquid oxygen portion of the ET. Large computer storage requirements and running times were required unless these procedures were modified. Several possibilities were demonstrated including the substitution of the real for the complex eigenvalue routine and the use of the OMIT capability to reduce the number of fluid coordinates. A NASTRAN model of the complete ET was formed and reduced to 252 degrees of freedom. A review of the eigenvector extracted, using the unsymmetrical inverse power method, indicated that the structural OMIT's resulted in unsatisfactory modal deflections. Modifications to the NASTRAN hydroelastic capability appeared necessary to generate a successful ET model. An approach is described which, by assuming incompressibility, reduces the fluid representation to a symmetric mass matrix which can be added to the structural mass. The problem is solved using faster and more efficient eigenvalue routines. Using this approach the ET NASTRAN model was analyzed for three separate weight conditions.

Bernstein, M.↗
NASA NTRS2000

Physics of Hard Spheres Experiment: Significant and Quantitative Findings Made

Direct examination of atomic interactions is difficult. One powerful approach to visualizing atomic interactions is to study near-index-matched colloidal dispersions of microscopic plastic spheres, which can be probed by visible light. Such spheres interact through hydrodynamic and Brownian forces, but they feel no direct force before an infinite repulsion at contact. Through the microgravity flight of the Physics of Hard Spheres Experiment (PHaSE), researchers have sought a more complete understanding of the entropically driven disorder-order transition in hard-sphere colloidal dispersions. The experiment was conceived by Professors Paul M. Chaikin and William B. Russel of Princeton University. Microgravity was required because, on Earth, index-matched colloidal dispersions often cannot be density matched, resulting in significant settling over the crystallization period. This settling makes them a poor model of the equilibrium atomic system, where the effect of gravity is truly negligible. For this purpose, a customized light-scattering instrument was designed, built, and flown by the NASA Glenn Research Center at Lewis Field on the space shuttle (shuttle missions STS 83 and STS 94). This instrument performed both static and dynamic light scattering, with sample oscillation for determining rheological properties. Scattered light from a 532- nm laser was recorded either by a 10-bit charge-coupled discharge (CCD) camera from a concentric screen covering angles of 0 to 60 or by sensitive avalanche photodiode detectors, which convert the photons into binary data from which two correlators compute autocorrelation functions. The sample cell was driven by a direct-current servomotor to allow sinusoidal oscillation for the measurement of rheological properties. Significant microgravity research findings include the observation of beautiful dendritic crystals, the crystallization of a "glassy phase" sample in microgravity that did not crystallize for over 1 year in 1g (Earth's gravity), and the emergence of face-centered-cubic (FCC) crystals late in the coarsening process (as small crystallites lost particles to the slow ripening of large crystallites). Significant quantitative findings from the microgravity experiments have been developed describing complex interactions among crystallites during the growth process, as concentration fields overlap in the surrounding disordered phase. Time-resolved Bragg scattering under microgravity captures one effect of these interactions quite conclusively for the sample at a volume fraction of 0.528. From the earliest time until the sample is almost fully crystalline, the size and overall crystallinity grow monotonically, but the number of crystallites per unit volume (number density) falls. Apparently nucleation is slower than the loss of crystallites because of the transfer of particles from small to large crystals. Thus, coarsening occurs simultaneously with growth, rather than following the completion of nucleation and growth as is generally assumed. In the same sample, an interesting signature appears in the apparent number density of crystallites and the volume fraction within the crystallites shortly before full crystallinity is reached. A brief upturn in both indicates the creation of more domains of the size of the average crystallite simultaneous with the compression of the crystallites. Only the emergence of dendritic arms offers a reasonable explanation. The arms would be "seen" by the light scattering as separate domains whose smaller radii of curvature would compress the interior phase. In fiscal year 1999, numerous papers, a doctoral dissertation, and the PHaSE final report were produced. Although this flight project has been completed, plans are in place for a follow-on colloid experiment by Chaikin and Russel that employs a light microscope within Glenn's Fluids and Combustion Facility on the International Space Station. PHaSE is providing us with a deeper understanding of the nure of phase transitions. The knowledge derived has added to the understanding of condensed matter. In addition, the burgeoning study of the dynamics of colloidal self-assembly may lead to the development of a range of photonic materials that control the desirable properties of light. Thus, applications of ordered colloidal structures include not only ultrastructure ceramics, but also photonic crystals and photothermal nanosecond light-switching devices. Industries dealing with semiconductors, electro-optics, ceramics, and composites stand to benefit from such advancements.

Doherty, Michael P.↗
NASA NTRS1993

Impeller flow field characterization with a laser two-focus velocimeter

Use of Computational Fluid Dynamics (CFD) codes, prevalent in the rocket engine turbomachinery industry, necessitates data of sufficient quality and quantity to benchmark computational codes. Existing data bases for typical rocket engine configurations, in particular impellers, are limited. In addition, traditional data acquisition methods have several limitations: typically transducer uncertainties are 0.5% of transducer full scale and traditional pressure probes are unable to provide flow characteristics in the circumferential (blade-to-blade) direction. Laser velocimetry circumvents these limitations by providing +0.5% uncertainty in flow velocity and +0.5% uncertainty in flow angle. The percent of uncertainty in flow velocity is based on the measured value, not full range capability. The laser electronics multiple partitioning capability allows data acquired between blades as the impeller rotates, to be analyzed separately, thus providing blade-to-blade flow characterization. Unlike some probes, the non-intrusive measurements made with the laser velocimeter does not disturb the flow. To this end,, and under Contract (NAS8-38864) to the National Aeronautics and Space Administration (NASA) at Marshall Space Flight Center (MSFC), an extensive test program was undertaken at Rocketdyne. Impellers from two different generic rocket engine pump configurations were examined. The impellers represent different spectrums of pump design: the Space Shuttle Main Engine (SSME) high pressure fuel turbopump (HPFTP) impeller was designed in the 1 1970's the Consortium for CFD application in Propulsion Technology Pump Stage Technology Team (Pump Consortium) optimized impeller was designed with the aid of modern computing techniques. The tester configuration for each of the impellers consisted of an axial inlet, an inducer, a diffuser, and a crossover discharge. While the tested configurations were carefully chosen to be representative of generic rocket engine pumps, several features of both testers were intentionally atypical. A crossover discharge, downstream of the impeller, rather than a volute discharge was used to minimize asymmetric flow conditions that might be reflected in the impeller discharge flow data. Impeller shroud wear ring radial clearances were purposely close to minimize leakage flow, thus increasing confidence in using the inlet data as an input to CFD programs. The empirical study extensively examined the flow fields of the two impellers via performance of laser two-focus velocimeter surveys in an axial plane upstream of the impellers and in multiple radial planes downstream of the impellers. Both studies were performed at the impeller design flow coefficients. Inlet laser surveys that provide CFD code inlet boundary conditions were performed in one axial plane, with ten radial locations surveyed. Three wall static pressures, positioned circumferentially around the impeller inlet, were used to identify asymmetrical pressure distributions in the inlet survey plane. The impeller discharge flow characterization consisted of three radial planes for the SSME HPFTP impeller and two radial planes for the Pump Consortium optimized impeller. Housing wall static pressures were placed to correspond to the radial locations surveyed with the laser velocimeter. Between five and thirteen axial stations across the discharge channel width were examined in each radial plane during the extensive flow mapping. The largely successful empirical flow characterization of two different impellers resulted in a substantial contribution to the limited existing data base, and yielded accurate data for CFD code benchmarking.

Brozowski, L. A.↗
NASA NTRS2014

Dual Fan Separator within the Universal Waste Management System

Since NASA's new spacecraft in development for both LEO and Deep Space capability have considerable crew volume reduction in comparison to the Space Shuttle, it is clear that NASA requires a smaller and less expensive commode. The UTAS Universal Waste Management System (UWMS) was designed to address these new constraints, resulting in an 80% volume reduction in the cabin while enhancing performance. Whereas all of the current space commodes use air flow to capture both urine and feces and separate air from the captured air/urine mixture, the UWMS commode and urine fans and the urine separator were combined into a single unit. This unit enables use of a single motor and motor controller, which provides considerable packaging and weight efficiency. In some of the intended platform applications for the UWMS, the urine is pumped to a water reclamation system. The ISS Urine Processor Assembly (UPA) system requires delivered urine to include less than 0.25% air inclusion. Air inclusion in centrifugal urine separators is greatly dependent on its rotational speed. To satisfy this requirement, a gear reducer was included, allowing the fans to rotate at a much higher speed than the separator. This new design, the Dual Fan Separator (DFS) has been designed, prototyped and tested. This paper will outline the studies and analysis performed to develop the design configuration for testing. The studies included a configuration trade study, dynamic stability analysis of the rotating bodies and a performance analysis of included labyrinth seals. NASA is considereing a program to fly the UWMS aboard the ISS as a flight experiment. The goal of the design activity is to elevate the Technical Readiness Level (TRL) of the Dual Fan Separator and determine if the concept is ready to be included in flight experiment deliverable.

Stapleton, Tom↗
NASA NTRS2014

Dual Fan Separator within the Universal Waste Management System

Since NASA's new spacecraft in development for both LEO and Deep Space capability have considerable crew volume reduction in comparison to the Space Shuttle, the need became apparent for a smaller commode. In response the Universal Waste Management System (UWMS) was designed, resulting in an 80% volume reduction from the last US commode, while enhancing performance. The ISS WMS and previous shuttle commodes have a fan supplying air flow to capture feces and a separator to capture urine and separate air from the captured air/urine mixture. The UWMS combined both rotating equipment components into a single unit, referred to at the Dual Fan Separator (DFS). The combination of these components resulted in considerable packaging efficiency and weight reduction, removing inter-component plumbing, individual mounting configurations and required only a single motor and motor controller, in some of the intended UWMS platform applications the urine is pumped to the ISS Urine Processor Assembly (UPA) system. It requires the DFS to include less than 2.00% air inclusion, by volume, in the delivered urine. The rotational speed needs to be kept as low as possible in centrifugal urine separators to reduce air inclusion in the pumped fluid, while fans depend on rotational speed to develop delivered head. To satisfy these conflicting requirements, a gear reducer was included, allowing the fans to rotate at a much higher speed than the separator. This paper outlines the studies and analysis performed to develop the DFS configuration. The studies included a configuration trade study, dynamic stability analysis of the rotating bodies and a performance analysis of included labyrinth seals. NASA is considering a program to fly the UWMS aboard the ISS as a flight experiment. The goal of this activity is to advance the Technical Readiness Level (TRL) of the DFS and determine if the concept is ready to be included as part of the flight experiment deliverable.

Stapleton, Tom↗
NASA NTRSDate not supplied

Flight Performance and Stability of Space Launch System Core Stage Thrust Vector Control

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. The Core Stage TVC shares vehicle control authority with the SLS 5-segment Solid Rocket Boosters (SRBs) during boost phase flight, and is the sole means of vehicle flight control during in exoatmospheric flight following SRB separation. TVC responses during Green Run Hot Fire (GRHF) testing revealed that the TVC did not meet its performance specifications. Step and frequency responses exhibited unexpected departures from prior laboratory data and modeled behavior. Post-test analysis determined that the characteristics of the structure and gimbal friction are significantly influenced by the thrust-loaded conditions, and the command avionics exhibited a small but important gain nonlinearity. Using the available test data, the design team augmented the flight control TVC models to bound the observed results and include the additional fidelity needed for vehicle flight control analysis so as to build sufficient rationale for flight certification. Prior to the Green Run tests, “simplex” linear models typically used for flight control analysis did not include gimbal friction and other nonlinearities owing to long-standing assumptions that these effects were negligible in the Shuttle Orbiter TVC system. Following the Green Run findings, simulation analysis of the flight dynamics in the time and frequency domain revealed the propensity for a flight control limit cycle oscillation (LCO) if friction and structural compliances fell near the edges of test-predicted bounds. While the “most probable” models did not predict an in-flight LCO, the SLS Program conservatively proceeded with a system-wide evaluation and ultimate acceptance of the possibility for a small amplitude, low-frequency TVC LCO in flight. A final validation of the extensive test and modeling effort occurred when the first flight of SLS successfully demonstrated the fully integrated performance of the vehicle’s TVC system This paper is the final installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the development of flight rationale in light of the TVC responses observed in Green Run is discussed, along with a review of the flight telemetry illustrating the correlation of the preflight predictions with the observed performance.

John H. Wall↗
NASA NTRS2012

SRMS Assisted Docking and Undocking for the Orbiter Repair Maneuver

As part of the Orbiter Repair Maneuver (ORM) planned for Return to Flight (RTF) operations, the Shuttle Remote Manipulator System (SRMS) must undock the Orbiter, maneuver it through a complex trajectory at extremely low rates, present it to an EVA crewman at the end of the Space Station Remote Manipulator System to perform the Thermal Protection System (TPS) repair, and then retrace back through the trajectory to dock the Orbiter with the Orbiter Docking System (ODS). The initial and final segments of this operation involve the interaction between the SRMS, ISS, Orbiter and ODS. Previously, a technique entitled "SRMS assisted docking" for installation of a payload to the ODS had been developed and was utilized for the Russian provided Docking Module on STS-74 during Shuttle-Mir missions and both the Node 1 and FGB elements on STS-88/Flight 2A. This procedure consisted of the SRMS grappling the respective payload, maneuvering it to a pre-install position inches above the ODS Androgynous Peripheral Attachment System (APAS) ring, commanding the SRMS into Test mode (which allows brakes-off motion of the joints), and then down-firing Primary Reaction Control System (PRCS) jets in order to effect a capture of the APAS latches. Once a successful capture had been achieved, then the AP AS was operated through its nominal retraction sequence to complete the mating sequence. While this technique can once again be used for the tail end docking portion of the ORM, the initial undocking of the orbiter and ISS vehicles with the assistance of the SRMS has yet to be attempted on orbit. The objective here is to determine the most efficient means to separate or extract the vehicles. Two techniques were analyzed in support of RTF: (1) the 'nominal' demating from the mated interface, and (2) the SRMS performing the operation (either in an active or passive fashion). In the first operation, the demating process would replicate standard undocking operations, with the exception that the SRMS is allowed to arrest the resulting motion. The second operation would be to extend the APAS ring to a ready to dock position, open the capture latches, and then detach the vehicles using the SRMS either actively or passively. In the active case, the APAS ring is extended and latched, and the SRMS is commanded to pull the two interfaces apart (assuming that the effective pull force of the SRMS can overcome the spec values of the combined latch resistance). In the passive case, the SRMS brakes are engaged and the AP AS mechanism is commanded to retract, pulling the two interfaces apart. Since the emphasis of both STS-74 and STS-88 had solely been on the installation operation, as opposed to the separation operation, two new models required development and incorporation within simulation tools designed to analyze those scenarios. These enhancements included: (1) a detailed demating dynamics model to characterize the pusher spring characteristics during undocking, and (2) contact and mechanical system modeling of the back side of the latches to represent unlatching dynamics. This paper first provides an overview of the Monte-Carlo screening analysis for the installation (both nominal and contingency), including the variation of separation distance, misalignment conditions, SRMS joint/brake parameter characteristics, and PRCS jet combinations and corresponding thrust durations. The resulting 'optimum' solution is presented based on trade studies between predicted capture success and integrated system loads. This paper then discusses the upgrades to the APAS math model associated with the new SRMS assisted undocking technique and reviews simulation results for various options investigated for either the active and passive separation of the ISS from the Orbiter.

Space Station Remote Manipulator System↗
NASA NTRS2011

Water Impact Prediction Tool for Recoverable Rockets

Reusing components from a rocket launch can be cost saving. NASA's space shuttle system has reusable components that return to the Earth and impact the ocean. A primary example is the Space Shuttle Solid Rocket Booster (SRB) that descends on parachutes to the Earth after separation and impacts the ocean. Water impact generates significant structural loads that can damage the booster, so it is important to study this event in detail in the design of the recovery system. Some recent examples of damage due to water impact include the Ares I-X First Stage deformation as seen in Figure 1 and the loss of the SpaceX Falcon 9 First Stage.To ensure that a component can be recovered or that the design of the recovery system is adequate, an adequate set of structural loads is necessary for use in failure assessments. However, this task is difficult since there are many conditions that affect how a component impacts the water and the resulting structural loading that a component sees. These conditions include the angle of impact with respect to the water, the horizontal and vertical velocities, the rotation rate, the wave height and speed, and many others. There have been attempts to simulate water impact. One approach is to analyze water impact using explicit finite element techniques such as those employed by the LS-Dyna tool [1]. Though very detailed, this approach is time consuming and would not be suitable for running Monte Carlo or optimization analyses. The purpose of this paper is to describe a multi-body simulation tool that runs quickly and that captures the environments a component might see. The simulation incorporates the air and water interaction with the component, the component dynamics (i.e. modes and mode shapes), any applicable parachutes and lines, the interaction of winds and gusts, and the wave height and speed. It is capable of quickly conducting Monte Carlo studies to better capture the environments and genetic algorithm optimizations to reproduce a flight.

Rooker, William↗
NASA NTRS2013

GFEChutes Lo-Fi

NASA needed to provide a software model of a parachute system for a manned re-entry vehicle. NASA has parachute codes, e.g., the Descent Simulation System (DSS), that date back to the Apollo Program. Since the space shuttle did not rely on parachutes as its primary descent control mechanism, DSS has not been maintained or incorporated into modern simulation architectures such as Osiris and Antares, which are used for new mission simulations. GFEChutes Lo-Fi is an object-oriented implementation of conventional parachute codes designed for use in modern simulation environments. The GFE (Government Furnished Equipment), low-fidelity (Lo-Fi) parachute model (GFEChutes Lo-Fi) is a software package capable of modeling the effects of multiple parachutes, deployed concurrently and/or sequentially, on a vehicle during the subsonic phase of reentry into planetary atmosphere. The term "low-fidelity" distinguishes models that represent the parachutes as simple forces acting on the vehicle, as opposed to independent aerodynamic bodies. GFEChutes Lo-Fi was created from these existing models to be clean, modular, certified as NASA Class C software, and portable, or "plug and play." The GFE Lo-Fi Chutes Model provides basic modeling capability of a sequential series of parachute activities. Actions include deploying the parachute, changing the reefing on the parachute, and cutting away the parachute. Multiple chutes can be deployed at any given time, but all chutes in that case are assumed to behave as individually isolated chutes; there is no modeling of any interactions between deployed chutes. Drag characteristics of a deployed chute are based on a coefficient of drag, the face area of the chute, and the local dynamic pressure only. The orientation of the chute is approximately modeled for purposes of obtaining torques on the vehicle, but the dynamic state of the chute as a separate entity is not integrated - the treatment is simply an approximation. The innovation in GFEChutes Lo-Fi is to use an object design that closely followed the mechanical characteristics and structure of a physical system of parachutes and their deployment mechanisms. Software objects represent the components of the system, and use of an object hierarchy allows a progression from general component outlines to specific implementations. These extra chutes were not part of the baseline deceleration sequence of drogues and mains, but still had to be simulated. The major innovation in GFEChutes Lo-Fi is the software design and architecture.

Gist, Emily↗
NASA NTRS2007

The Ares I-1 Flight Test--Paving the Road for the Ares I Crew Launch Vehicle

In accordance with the U.S. Vision for Space Exploration and the nation's desire to again send humans to explore beyond Earth orbit, NASA has been tasked to send human beings to the moon, Mars, and beyond. It has been 30 years since the United States last designed and built a human-rated launch vehicle. NASA is now building the Ares I crew launch vehicle, which will loft the Orion crew exploration vehicle into orbit, and the Ares V cargo launch vehicle, which will launch the Lunar Surface Access Module and Earth departure stage to rendezvous Orion for missions to the moon. NASA has marshaled unique resources from the government and private sectors to perform the technically and programmatically complex work of delivering astronauts to orbit early next decade, followed by heavy cargo late next decade. Our experiences with Saturn and the Shuttle have taught us the value of adhering to sound systems engineering, such as the "test as you fly" principle, while applying aerospace best practices and lessons learned. If we are to fly humans safely aboard a launch vehicle, we must employ a variety of methodologies to reduce the technical, schedule, and cost risks inherent in the complex business of space transportation. During the Saturn development effort, NASA conducted multiple demonstration and verification flight tests to prove technology in its operating environment before relying upon it for human spaceflight. Less testing on the integrated Shuttle system did not reduce cost or schedule. NASA plans a progressive series of demonstration (ascent), verification (orbital), and mission flight tests to supplement ground research and high-altitude subsystem testing with real-world data, factoring the results of each test into the next one. In this way, sophisticated analytical models and tools, many of which were not available during Saturn and Shuttle, will be calibrated and we will gain confidence in their predictions, as we gain hands-on experience in operating the first of two new launch vehicle systems. The Ares I-1 flight test vehicle (FTV) will incorporate a mix of flight and mockup hardware, reflecting a configuration similar in mass, weight, and shape (outer mold line or OML) to the operational vehicle. It will be powered by a four-segment reusable solid rocket booster (RSRB), which is currently in Shuttle inventory, and will be modified to include a fifth, inert segment that makes it approximately the same size and weight as the five segment RSRB, which will be available for the second flight test in 2012. The Ares I-1 vehicle configuration is shown. Each test flight has specific objectives appropriate to the design analysis cycle in progress. The Ares I-1 demonstration test, slated for April 2009, gives NASA its first opportunity to gather critical data about the flight dynamics of the integrated launch vehicle stack, understand how to control its roll during flight, and other characterize the severe stage separation environment that the upper stage will experience during future operational flights. NASA also will begin the process of modifying the launch infrastructure and fine-tuning ground and mission operational scenarios, as NASA transitions from the Shuttle to the Ares/Orion system.

Davis, Stephan R.↗
NASA NTRS2009

Synergistic Development, Test, and Qualification Approaches for the Ares I and V Launch Vehicles

The U.S. National Aeronautics and Space Administration is designing and developing the Ares I and Ares V launch vehicles for access to the International Space Station (ISS) and human exploration of the Moon. The Ares I consists of a first stage reusable five-segment solid rocket booster, a upper stage using a J-2X engine derived from heritage experience (Saturn and Space Shuttle External Tank programs), and the Orion crew exploration vehicle (CEV). The Ares V is designed to minimize the development and overall life-cycle costs by leveraging off of the Ares I design. The Ares V consists of two boosters, a core stage, an earth departure stage (EDS), and a shroud. The core stage and EDS use LH2/LO2 propellants, metallic propellant tanks, and composite dry structures. The core stage has six RS-68B upgraded Delta IV engines while the EDS uses a J-2X engine for second stage ascent and trans-lunar injection (TLI) burn. System and propulsion tests and qualification approaches for Ares V elements are being considered as follow-on extensions of the Ares I development program. Following Ares I IOC, testing will be conducted to verify the J-2X engine's orbital restart and TLI burn capability. The Ares I upper stage operation will be demonstrated through integrated stage development and acceptance testing. The EDS will undergo similar development and acceptance testing with additional testing to verify aspects of cryogenic propellant management, operation of sub-systems in a space simulation environment, and orbital re-start of the main propulsion system. RS-68B certification testing will be conducted along with integrated core stage development and acceptance testing. Structural testing of the Ares V EDS and core stage propellant tanks will be conducted similar to the Ares I upper stage. The structural qualification testing may be accomplished with separate propellant tank test articles. Structural development and qualification testing of the dry structure will be pursued as part of the design and development process. Especially critical is the development test program for the composite structures. The Ares V payload shroud will undergo acoustic, vibration, structural qualification, and deployment testing in a space simulation environment. Similar to Ares I, requirements for full-scale structural dynamic testing are being studied. Both Ares I and Ares V include validation flight testing as part of the qualification programs.

Cockrell, Charles E.↗
NASA NTRS1992

Hydrogen leak detection in the Space Shuttle

This study focuses on a helium gas jet flowing into room air. Measurements of helium concentration and velocity in the jet-air mixture are reported. The objective is to learn about jet characteristics so that dynamically similar hydrogen leaks may be located in the Space Shuttle. The hazardous gas detection system (HGDS) in the mobile launch pad uses mass spectrometers to monitor the shuttle environment for leaks. The mass spectrometers are fed by long sample tubes which draw gas from the payload bay, mid body, aft engine compartment and external tank. The overall purpose of this study is to improve the HGDS especially in its potential for locating hydrogen leaks. A rapid-response leak detection experiment was designed, built, and tested, following on the work done in this program last summer. The apparatus included a Perkin Elmer MGA-1200 mass spectrometer and air velocity transducer, both monitored by a Macintosh IIFX computer using LabVIEW software. A jet of helium flowing into the lab air simulated a gas leak. Steady helium or hydrogen-nitrogen jets were logged for concentration and velocity, and the power spectral density of each was computed. Last year, large eddies and vortices were visually seen with Schlieren imaging, and they were detected in the time plots of the various instruments. The response time of the MGA-1200 was found in the range of 0.05 to 0.1 sec. Pulsed concentration waves were clearly detected at 25 cycles per sec by spectral analysis of MGA data. No peaks were detected in the power spectrum, so in the present study, 10 Hz bandwidth-averaged power levels were examined at regular frequency intervals. The practical consequences of last year's study are as follows: sampling frequency should be increased above the present rate of 1 sample per second so that transients could be observed and analyzed with frequency response methods. Many more experiments and conditions were observed in this second summer, including the effects of orifice diameter, jet velocity, sample tube design, radial effects, vertical flow, and low hydrogen concentrations (1 percent). A frequent observation was that the power spectrum, calculated from the Fourier transform of concentration fluctuations, gives a separate piece of information from concentration. Many of the tests suggest that power is high where mixing occurs at the helium-air interface. This fact is apparently independent of the concentration level, which could be high or low, but depends on the sample location relative to the jet (leak) origin, whereas high concentration may be due to a strong leak far away or a small leak close to the sample tube. If the power is low for any concentration level, this would signify helium is arriving at the sample tube by diffusion, not chaotic mixing caused by the jet interaction with air. The practical result is to propose a modification of the HGDL mass spectrometer data sampling and software so that sampling rates could be capable of observing at least 25 Hz fluctuations.

Barile, Ronald G↗