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NASA NTRS2006

Integrated System Health Management (ISHM) Technology Demonstration Project Final Report

Integrated System Health Management (ISHM) is an essential capability that will be required to enable upcoming explorations mission systems such as the Crew Exploration Vehicle (CEV) and Crew Launch Vehicle (CLV), as well as NASA aeronautics missions. However, the lack of flight experience and available test platforms have held back the infusion by NASA Ames Research Center (ARC) and the Jet Propulsion Laboratory (JPL) of ISHM technologies into future space and aeronautical missions. To address this problem, a pioneer project was conceived to use a high-performance aircraft as a low-cost proxy to develop, mature, and verify the effectiveness of candidate ISHM technologies. Given the similarities between spacecraft and aircraft, an F/A-18 currently stationed at Dryden Flight Research Center (DFRC) was chosen as a suitable host platform for the test bed. This report describes how the test bed was conceived, how the technologies were integrated on to the aircraft, and how these technologies were matured during the project. It also describes the lessons learned during the project and a forward path for continued work.

Mackey, Ryan↗

NASA NTRS2007

Lithium Iron Phosphate Cell Performance Evaluations for Lunar Extravehicular Activities

Lithium-ion battery cells are being evaluated for their ability to provide primary power and energy storage for NASA s future Exploration missions. These missions include the Orion Crew Exploration Vehicle, the Ares Crew Launch Vehicle Upper Stage, Extravehicular Activities (EVA, the advanced space suit), the Lunar Surface Ascent Module (LSAM), and the Lunar Precursor and Robotic Program (LPRP), among others. Each of these missions will have different battery requirements. Some missions may require high specific energy and high energy density, while others may require high specific power, wide operating temperature ranges, or a combination of several of these attributes. EVA is one type of mission that presents particular challenges for today s existing power sources. The Portable Life Support System (PLSS) for the advanced Lunar surface suit will be carried on an astronaut s back during eight hour long sorties, requiring a lightweight power source. Lunar sorties are also expected to occur during varying environmental conditions, requiring a power source that can operate over a wide range of temperatures. Concepts for Lunar EVAs include a primary power source for the PLSS that can recharge rapidly. A power source that can charge quickly could enable a lighter weight system that can be recharged while an astronaut is taking a short break. Preliminary results of Al23 Ml 26650 lithium iron phosphate cell performance evaluations for an advanced Lunar surface space suit application are discussed in this paper. These cells exhibit excellent recharge rate capability, however, their specific energy and energy density is lower than typical lithium-ion cell chemistries. The cells were evaluated for their ability to provide primary power in a lightweight battery system while operating at multiple temperatures.

Reid, Concha↗

NASA NTRS2008

Summary of Propulsion System Needs in Support of Project Constellation

In January 2004, the President of the United States established the Vision for Space Exploration (VSE) to return man to the moon and ultimately to extend manned space travel to Mars. This paper will summarize the manned space flight liquid propulsion system needs in support of Project Constellation over the next 10 years. It will include all engine needs to return man to the moon. An overview of engines currently under contract, those baselined but not yet under contract, and those engine needs that hav.e yet to be initiated. Project Constellation includes the components as shown Figure 1. Liquid propulsion systems supporting the manned portion of these elements include the following: the Crew Exploration Vehicle named Orion (crew module reaction control system (CMRCS), service module Orion Main Engine (OME), service module auxiliary RCS, and service module reaction control system (SMRCS)), the Crew Launch Vehicle named Ares 1 (J2X upper stage, first stage roll control system, second stage reaction control system, and the Ares I-X roll control system), the Heavy Lift Launch Vehicle named Ares V (RS68B first stage booster, J-2X upper stage, roll control systems, and the Earth Departure Stage (EDS) (powered by the same Ares V Upper Stage J-2X), and the Lunar Lander named Altair with both descent and ascent stages (lunar orbit insertion and descent main engine, ascent main engine, and attitude control systems for both stages). In addition, there may be additional engine needs for early demonstrators, but those will not be speculated on as part of this paper. Also, other portions of the VSE architecture, including the planned Orion abort demonstrations and the Lunar Precursor Robotic Program, are not addressed here as they either use solid motors or are focused on unmanned precursor missions.

Sumrall, Phil↗

NASA NTRS2010

Ares I-X Launch Abort System, Crew Module, and Upper Stage Simulator Vibroacoustic Flight Data Evaluation, Comparison to Predictions, and Recommendations for Adjustments to Prediction Methodology and Assumptions

The National Aeronautics and Space Administration (NASA) Constellation Program (CxP) has identified a series of tests to provide insight into the design and development of the Crew Launch Vehicle (CLV) and Crew Exploration Vehicle (CEV). Ares I-X was selected as the first suborbital development flight test to help meet CxP objectives. The Ares I-X flight test vehicle (FTV) is an early operational model of CLV, with specific emphasis on CLV and ground operation characteristics necessary to meet Ares I-X flight test objectives. The in-flight part of the test includes a trajectory to simulate maximum dynamic pressure during flight and perform a stage separation of the Upper Stage Simulator (USS) from the First Stage (FS). The in-flight test also includes recovery of the FS. The random vibration response from the ARES 1-X flight will be reconstructed for a few specific locations that were instrumented with accelerometers. This recorded data will be helpful in validating and refining vibration prediction tools and methodology. Measured vibroacoustic environments associated with lift off and ascent phases of the Ares I-X mission will be compared with pre-flight vibration predictions. The measured flight data was given as time histories which will be converted into power spectral density plots for comparison with the maximum predicted environments. The maximum predicted environments are documented in the Vibroacoustics and Shock Environment Data Book, AI1-SYS-ACOv4.10 Vibration predictions made using statistical energy analysis (SEA) VAOne computer program will also be incorporated in the comparisons. Ascent and lift off measured acoustics will also be compared to predictions to assess whether any discrepancies between the predicted vibration levels and measured vibration levels are attributable to inaccurate acoustic predictions. These comparisons will also be helpful in assessing whether adjustments to prediction methodologies are needed to improve agreement between the predicted and measured flight data. Future assessment will incorporate hybrid methods in VAOne analysis (i.e., boundary element methods, BEM and finite element methods, FEM). These hybrid methods will enable the ability to import NASTRAN models providing much more detailed modeling of the underlying beams and support structure of the ARES 1-X test vehicle. Measured acoustic data will be incorporated into these analyses to improve correlation for additional post flight analysis.

Smith, Andrew↗

NASA NTRS2009

Cluster Development Test 2: An Assessment of a Failed Test

On 31 July 2008 the National Aeronautics and Space Administration Crew Exploration Vehicle Parachute Assembly System team conducted the final planned cluster test of the first generation parachute recovery system design. The two primary test objectives were to demonstrate the operation of the complete parachute system deployed from a full scale capsule simulator and to demonstrate the test technique of separating the capsule simulator from the Low Velocity Air Drop pallet used to extract the test article from a United States Air Force C-17 aircraft. The capsule simulator was the Parachute Test Vehicle with an accurate heat shield outer mold line and forward bay compartment of the Crew Exploration Vehicle Command Module. The Parachute Test Vehicle separated cleanly from the pallet following extraction, but failed to reach test conditions resulting in the failure of the test and the loss of the test assets. No personnel were injured. This paper will discuss the design of the test and the findings of the team that investigated the test, including a discussion of what were determined to be the root causes of the failure.

Machin, Ricardo A.↗

NASA NTRS2008

NASA's Ares I and Ares V Launch Vehicles -- Effective Space Operations Through Efficient Ground Operations

The United States (U.S.) plans to return to the Moon by 2020, with the development of a new human-rated space transportation system to replace the Space Shuttle, which is due for retirement in 2010 after it completes its missions of building the International Space Station and servicing the Hubble Space Telescope. Powering the future of space-based scientific exploration will be the Ares I Crew Launch Vehicle, which will transport the Orion Crew Exploration Vehicle to orbit where it will rendezvous with the Lunar Lander. which will be delivered by the Ares V Cargo Launch Vehicle. This new transportation infrastructure, developed by the National Aeronautics and Space Administration (NASA), will allow astronauts to leave low-Earth orbit for extended lunar exploration and preparation for the first footprint on Mars. All space-based operations begin and are controlled from Earth. NASA's philosophy is to deliver safe, reliable, and cost-effective solutions to sustain a multi-billion-dollar program across several decades. Leveraging 50 years of lessons learned, NASA is partnering with private industry, while building on proven hardware experience. This paper will discuss how the Engineering Directorate at NASA's Marshall Space Flight Center is working with the Ares Projects Office to streamline ground operations concepts and reduce costs. Currently, NASA's budget is around $17 billion, which is less than 1 percent of the U.S. Federal budget. Of this amount, NASA invests approximately $4.5 billion each year in Space Shuttle operations, regardless of whether the spacecraft is flying or not. The affordability requirement is for the Ares I to reduce this expense by 50 percent, in order to allow NASA to invest more in space-based scientific operations. Focusing on this metric, the Engineering Directorate provides several solutions-oriented approaches, including Lean/Six Sigma practices and streamlined hardware testing and integration, such as assembling major hardware elements before shipping to the Kennedy Space Center for launch operations. This paper provides top-level details for several cost saving initiatives, including both process and product improvements that will result in space transportation systems that are designed with operations efficiencies in mind. The Engineering Directorate provides both the intellectual capital embodied in an experienced workforce and unique facilities in which to validate the information technology tools that allow a nationwide team to collaboratively connect across miles that separate them and the engineering disciplines that integrate various piece parts into a whole system. As NASA transforms ground-based operations, it also is transitioning its workforce from an era of intense hands-on labor to a new one of mechanized conveniences and robust hardware with simpler interfaces. Ensuring that space exploration is on sound footing requires that operations efficiencies be designed into the transportation system and implemented in the development stage. Applying experience gained through decades of ground and space op'erations, while using value-added processes and modern business and engineering tools, is the philosophy upon which a new era of exploration will be built to solve some of the most pressing exploration challenges today -- namely, safety, reliability, and affordability.

Dumbacher, Daniel L.↗

NASA NTRS2008

NASA's Ares I and Ares V Launch Vehicles--Effective Space Operations Through Efficient Ground Operations

The United States (U.S.) is charting a renewed course for lunar exploration, with the fielding of a new human-rated space transportation system to replace the venerable Space Shuttle, which will be retired after it completes its missions of building the International Space Station (ISS) and servicing the Hubble Space Telescope. Powering the future of space-based scientific exploration will be the Ares I Crew Launch Vehicle, which will transport the Orion Crew Exploration Vehicle to orbit where it will rendezvous with the Altair Lunar Lander, which will be delivered by the Ares V Cargo Launch Vehicle (fig. 1). This configuration will empower rekindled investigation of Earth's natural satellite in the not too distant future. This new exploration infrastructure, developed by the National Aeronautics and Space Administration (NASA), will allow astronauts to leave low-Earth orbit (LEO) for extended lunar missions and preparation for the first long-distance journeys to Mars. All space-based operations - to LEO and beyond - are controlled from Earth. NASA's philosophy is to deliver safe, reliable, and cost-effective architecture solutions to sustain this multi-billion-dollar program across several decades. Leveraging SO years of lessons learned, NASA is partnering with private industry and academia, while building on proven hardware experience. This paper outlines a few ways that the Engineering Directorate at NASA's Marshall Space Flight Center is working with the Constellation Program and its project offices to streamline ground operations concepts by designing for operability, which reduces lifecycle costs and promotes sustainable space exploration.

Singer, Christopher E.↗

NASA NTRS2007

Developing Primary Propulsion for the Ares I Crew Launch Vehicle and Ares V Cargo Launch Vehicle

In accordance with the U.S. Vision for Space Exploration, NASA has been tasked to send human beings to the moon, Mars, and beyond. The first stage of NASA's new Ares I crew launch vehicle (Figure 1), which will loft the Orion crew exploration vehicle into low-Earth orbit early next decade, will consist of a Space Shuttle-derived five-segment Reusable Solid Rocket Booster (RSRB); a pair of similar RSRBs also will be used on the Ares V cargo launch vehicle's core stage propulsion system. This paper will discuss the basis for choosing this particular propulsion system; describe the activities the Exploration Launch Projects (ELP) Office is engaged in at present to develop the first stage; and offer a preview of future development activities related to the first Ares l integrated test flight, which is planned for 2009.

Priskos, Alex S.↗

NASA NTRS2007

The First Year in Review: NASA's Ares I Crew Launch Vehicle and Ares V Cargo Launch Vehicle

The U.S. Vision for Space Exploration guides NASA's challenging missions of scientific discovery.' Developing safe, reliable, and affordable space transportation systems for the human and robotic exploration of space is a key component of fulfilling the strategic goals outlined in the Vision, as well as in the U.S. Space Policy. In October 2005, the Exploration Systems Mission Directorate and its Constellation Program chartered the Exploration Launch Projects Office, located at the Marshall Space Flight Center, to design, develop, test, and field a new generation of launch vehicles that would fulfill customer and stakeholder requirements for trips to the Moon, Mars, and beyond. The Ares I crew launch vehicle is slated to loft the Orion crew exploration vehicle to orbit by 2014, while the heavy-lift Ares V cargo launch vehicle will deliver the lunar lander to orbit by 2020 (Fig. 1). These systems are being designed to empower America's return to the Moon to prepare for the first astronaut on Mars. The new launch vehicle designs now under study reflect almost 50 years of hard-won experience gained from the Saturn's missions to the Moon in the late 1960s and early 1970s, and from the venerable Space Shuttle, which is due to be retired by 2010.

Dumbacher, Daniel L.↗

NASA NTRS2009

Ascent Heating Thermal Analysis on the Spacecraft Adaptor (SA) Fairings and the Interface with the Crew Launch Vehicle (CLV)

When the crew exploration vehicle (CEV) is launched, the spacecraft adaptor (SA) fairings that cover the CEV service module (SM) are exposed to aero heating. Thermal analysis is performed to compute the fairing temperatures and to investigate whether the temperatures are within the material limits for nominal ascent aero heating case. Heating rates from Thermal Environment (TE) 3 aero heating analysis computed by engineers at Marshall Space Flight Center (MSFC) are used in the thermal analysis. Both MSC Patran 2007r1b/Pthermal and C&R Thermal Desktop 5.1/Sinda models are built to validate each other. The numerical results are also compared with those reported by Lockheed Martin (LM) and show a reasonably good agreement.

Wang, Xiao-Yen↗

NASA NTRS2006

NASA Exploration Launch Projects Systems Engineering Approach for Astronaut Missions to the Moon, Mars, and Beyond

The U.S. Vision for Space Exploration directs NASA to design and develop a new generation of safe, reliable, and cost-effective transportation systems to hlfill the Nation s strategic goals and objectives. These launch vehicles will provide the capability for astronauts to conduct scientific exploration that yields new knowledge from the unique vantage point of space. American leadership in opening new fi-ontiers will improve the quality of life on Earth for generations to come. The Exploration Launch Projects office is responsible for delivering the Crew Launch Vehicle (CLV) that will loft the Crew Exploration Vehicle (CEV) into low-Earth orbit (LEO) early next decade, and for the heavy lift Cargo Launch Vehicle (CaLV) that will deliver the Lunar Surface Access Module (LSAM) to LEO for astronaut return trips to the Moon by 2020 in preparation for the eventual first human footprint on Mars. Crew travel to the International Space Station will be made available as soon possible after the Space Shuttle retires in 2010.

Cook, Stephen A.↗

NASA NTRS2006

NASA Exploration Launch Projects Systems Engineering Approach for Astronaut Missions to the Moon, Mars, and Beyond

Dumbacher, Daniel L.↗

NASA NTRS2007

Testing Lunar Return Thermal Protection Systems using Sub-Scale Flight Test Vehicles

A key objective of NASA's Vision for Space Exploration is to revisit the lunar surface. Such an ambitious goal requires the development of a new human-rated spacecraft, the Orion Crew Exploration Vehicle (CEV), to ferry crews to low earth orbit and to the moon. The successful conclusion of both types of missions will require a thermal protection system (TPS) capable of protecting the vehicle and crew from the extreme heat of atmospheric reentry. As a part of the TPS development, various materials are being tested in arcjet tunnels; however, the combined lunar return aerothermal environment of high heat flux, shear stress, and surface pressure cannot be duplicated using only existing ground test facilities. To ensure full TPS qualification, a flight test program using sub-scale Orion capsules has been proposed to test TPS materials and heat shield construction techniques under the most stressing combination of lunar return aerothermal environments. Originally called Testing Of Reentry Capsule Heat Shield, or TORCH, but later renamed LEX, for Lunar Reentry Experiment, the proposed flight test program is presented along with the driving requirements and descriptions of the vehicle and the TPS instrumentation suite slated to conduct in-flight measurements.

heatshield↗

NASA NTRS2007

Methodology for Prototyping Increased Levels of Automation for Spacecraft Rendezvous Functions

The Crew Exploration Vehicle necessitates higher levels of automation than previous NASA vehicles, due to program requirements for automation, including Automated Rendezvous and Docking. Studies of spacecraft development often point to the locus of decision-making authority between humans and computers (i.e. automation) as a prime driver for cost, safety, and mission success. Therefore, a critical component in the Crew Exploration Vehicle development is the determination of the correct level of automation. To identify the appropriate levels of automation and autonomy to design into a human space flight vehicle, NASA has created the Function-specific Level of Autonomy and Automation Tool. This paper develops a methodology for prototyping increased levels of automation for spacecraft rendezvous functions. This methodology is used to evaluate the accuracy of the Function-specific Level of Autonomy and Automation Tool specified levels of automation, via prototyping. Spacecraft rendezvous planning tasks are selected and then prototyped in Matlab using Fuzzy Logic techniques and existing Space Shuttle rendezvous trajectory algorithms.

Hart, Jeremy J.↗

NASA NTRS2008

Determining Exercise Strength Requirements for Astronaut Critical Mission Tasks: Reaching Under G-Load

The critical mission tasks assessments effort seeks to determine the physical performance requirements that astronauts must meet in order to safely and successfully accomplish lunar exploration missions. These assessments will determine astronaut preflight strength, fitness, and flexibility requirements, and the extent to which exercise and other countermeasures must prevent the physical deconditioning associated with prolonged weightlessness. The purpose is to determine the flexibility and strength that crewmembers must possess in order to reach Crew Exploration Vehicle controls during maneuvers that result in sustained acceleration levels ranging from 3.7G to 7.8G. An industry standard multibody dynamics application was used to create human models representing a 5th percentile female, a 50th percentile male, and a 95th percentile male. The additional mass of a space suit sleeve was added to the reaching arm to account for the influence of the suit mass on the reaching effort. The human model was merged with computer models of a pilot seat and control panel for the Crew Exploration Vehicle. Three dimensional paths were created that guided the human models hand from a starting position alongside its thigh to three control targets: a joystick, a keyboard, and an overhead switch panel. The reaching motion to each target was repeated under four vehicle acceleration conditions: nominal ascent (3.7G), two ascent aborts (5.5G and 7.8G) and lunar reentry (4.6G). Elbow and shoulder joint angular excursions were analyzed to assess range of motion requirements. Mean and peak elbow and shoulder joint torques were determined and converted to equivalent resistive exercise loads to assess strength requirements. Angular excursions for the 50th and 95th percentile male models remained within joint range of motion limits. For the 5th percentile female, both the elbow and the shoulder exceeded range of motion limits during the overhead reach. Elbow joint torques ranged from 10 N-m (nominal ascent) to 60 N-m (ascent abort). Shoulder joint torques ranged from 65 N-m (nominal ascent) to 280 N-m (ascent abort). Maximal equivalent exercise loads reached 30 lb in tricep extension, 9 lb in bicep curl, 110 lb in unilateral pullover and unilateral bench press for nominal conditions (lunar reentry), and 188 lb in unilateral pullover and unilateral bench press. The location of the pilot seat was found to be inadequately located to allow a 5th percentile female to reach the switches on the overhead panel. Elbow strength requirements were found to be well within population norms. Shoulder strength was found to be a limiting factor. Reaching under nominal ascent and lunar reentry conditions was found to require near maximal shoulder strength. Reaching under ascent abort conditions requires shoulder strength well beyond population norms. Pilot seats must adjust to accomodate a 5th percentile female. Exercise countermeasures must maintain maximal pullover and bench press strength to allow pilots to reach and operate controls during lunar reentry. Reaching will not be possible during ascent abort conditions. Flight controls should be built into armrests or flight control must be accomplished by autonomous systems during acceleration exceeding 4.6G.

Schaffner, Grant↗

NASA NTRS2007

Wireless Sensor Needs in the Space Shuttle and CEV Structures Communities

This presentation will clarify some of the structural measurement needs of NASA's Space Shuttle and Crew Exploration Vehicles. Emerging technologies in wireless sensor systems can be of some advantage in both Programs. The presentation will address how wireless instrumentation has helped in the past and what has gone unmeasured on Shuttle due to various limitations. Finally, it will address the needs of the CEV program that can be met with reliable wireless systems, if modular avionics interfaces are provided to accommodate the usual evolving needs of an ambitious space vehicle development program. Examples of the advantages of flight data to support flight certification engineering analyses and of areas where add-on wireless instrumentation can be used will be shown. Without flight instrumentation, it is necessary to retain the conservative assumptions used in the design process. It will be shown how the lessons learned on Space Shuttle for wired and wireless structural measurements apply to the Orion Crew Exploration Vehicle (CEV), which is currently being designed.

James, George H., III↗

NASA NTRS2009

Human Systems Integration (HSI) Case Studies from the NASA Constellation Program

The National Aeronautics and Space Administration (NASA) Constellation Program is responsible for planning and implementing those programs necessary to send human explorers back to the moon, onward to Mars and other destinations in the solar system, and to support missions to the International Space Station. The Constellation Program has the technical management responsibility for all Constellation Projects, including both human rated and non-human rated vehicles such as the Crew Exploration Vehicle, EVA Systems, the Lunar Lander, Lunar Surface Systems, and the Ares I and Ares V rockets. With NASA s new Vision for Space Exploration to send humans beyond Earth orbit, it is critical to consider the human as a system that demands early and continuous user involvement, inclusion in trade offs and analyses, and an iterative "prototype/test/ redesign" process. Personnel at the NASA Johnson Space Center are involved in the Constellation Program at both the Program and Project levels as human system integrators. They ensure that the human is considered as a system, equal to hardware and software vehicle systems. Systems to deliver and support extended human habitation on the moon are extremely complex and unique, presenting new opportunities to employ Human Systems Integration, or HSI practices in the Constellation Program. The purpose of the paper is to show examples of where human systems integration work is successfully employed in the Constellation Program and related Projects, such as in the areas of habitation and early requirements and design concepts.

Baggerman, Susan↗

NASA NTRS2006

NASA Crew Launch Vehicle Overview

The US. Vision for Space Exploration, announced January 2004, outlines the National Aeronautics and Space Administration s (NASA) strategic goals and objectives. These include: 1) Flying the Shuttle as safely as possible until its retirement, not later than 2010. 2) Bringing a new Crew Exploration Vehicle (CEV) into service as soon as possible after Shuttle retirement. 3) Developing a balanced overall program of science, exploration, and aeronautics at NASA, consistent with the redirection of the human spaceflight program to focus on exploration. 4) Completing the International Space Station (ISS) in a manner consistent with international partner commitments and the needs of human exploration. 5) Encouraging the pursuit of appropriate partnerships with the emerging commercial space sector. 6) Establishing a lunar return program having the maximum possible utility for later missions to Mars and other destinations. Following the confirmation of the new NASA Administrator in April 2005, the Agency commissioned a team of aerospace subject matter experts from government and industry to perform the Exploration Systems Architecture Study (ESAS), which provided in-depth information for selecting the follow-on launch vehicle designs to enable these goals, The ESAS team analyzed a number of potential launch systems, with a focus on: (1) a human-rated launch vehicle for crew transport and (2) a heavy lift launch vehicle (HLLV) to carry cargo. After several months of intense study utilizing technical performance, budget, and schedule objectives, the results showed that the optimum architecture to meet the challenge of safe, reliable crew transport is a two-stage variant of the Space Shuttle propulsion system - utilizing the reusable Solid Rocket Booster (SRB) as the first stage, along with a new upper stage that uses a derivative of the RS-25 Space Shuttle Main Engine to deliver 25 metric tons to low-Earth orbit. The CEV that this new Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the Space Station and be capable of carrying crews back to lunar orbit and of supporting missions to Mars orbit. The HLLV system will utilize the Shuttle External Tank combined with SRBs. The focus of this paper is on the CLV system, giving an overview of plans and progress to date.

Dumbacher, Daniel L.↗