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NASA NTRS2020

Lessons Learned from Recent Space Flight Assessments

This paper highlights four space flight assessments, each with an important lesson. The first assessment points to the challenge of material substitution for weight saving. Space Shuttle’s external tank stringers were changed from Al 2024 to Al 2090 without comprehensive analysis. Lack of understanding the low Short-Transverse (S-T) strength associated with Al 2090 led to widespread cracking. The second assessment addresses the failure to understand that time-dependent relationships and loading interactions of multiple disciplines can lead to non-conservative results. An aerodynamic test article of the Orion Multi-Purpose Crew Vehicle (MPCV) Launch Abort System (LAS) was analyzed for worst-case single discipline loads, showing positive structural margins. When disciplines were combined with time dependent loading, the analysis resulted in negative margins. The third assessment highlights the pitfalls of putting blind trust in historical architecture. The MPCV re-entry heat shield adopted the Apollo design approach despite fundamental differences between the two designs (e.g., the underlying substructure design, material differences, scale, and geometry). Manufacturing resulted in cracking along seams of the cured MPCV heat shield and produced lower mechanical properties of the Avcoat witness panels. Subsequently, the design was changed to a block architecture, which introduced unperceived technical, cost, and schedule risk. The fourth assessment shows how the lack of a comprehensive investigation of design modifications and inappropriate Finite Element Analyses (FEA) can lead to trouble. A mass reduction campaign eliminated highly critical internal struts on the ISS Node-1 pressurized module based on inadequate and uncorrelated FEA. High strains were noted and ignored as a modeling aberration. A system level high fidelity FEA discovered large plastic strains in the gussets of all four radial ports. These findings initiated a full-scale test campaign, new test correlated assembly-level FEA, and significant design modifications.

James P Smith↗
NASA NTRSDate not supplied

An Agile-Like Approach to Hardware Development: The Ejectable Data Recorder (EDR) for Orion's Ascent Abort 2 (AA-2) Test Flight

On July 2, 2019, the Ascent Abort 2 (AA-2) Flight Test Vehicle was launched from Cape Canaveral, with the goal of demonstrating the performance of Orion’s Launch Abort System (LAS) and collecting data from hundreds of sensors throughout the vehicle. The data collected during this test flight is of paramount importance, as it will be used to certify the Orion vehicle for human spaceflight. Originally, the data was to be downlinked via a single string network of antennas on the LAS, with the associated risk of potential data dropouts, as well as loss of data once the LAS was jettisoned. Thus, additional antennas were added onto the crew module (CM) to support data downlink post-LAS jettison, a buffer rebroadcast capability was added to fill in any gaps in data downlink transmissions, and an ejectable data recorder (EDR) subsystem was added to the CM as a redundant measure to collect all the instrumentation data. The EDR subsystem was added to the project about one year after the project commenced, which significantly reduced the available development time when compared with the other subsystems of the AA-2 Test Flight. The project was further accelerated by six months, around the critical design review gate. Due to the schedule compression challenge and the fact that the EDR subsystem was a backup system and not flight critical, the EDR subsystem was further challenged to find a new and more efficient way to develop hardware. Thus, the EDR subsystem experimented with different management and systems engineering processes, team sizes, communication methods, and tools. Some examples are novel uses of SharePoint as a Data-centric Project Management & Systems Engineering environment, a continuous testing approach through the lifecycle, and a Skunkworks approach to managing the team. The EDR subsystem blended Commercial Off The Shelf (COTS) hardware with in-house developed hardware and software to create a novel data retrieval capability. The capability evolved rapidly through a hardware in the loop simulation environment that enabled incremental component updates for not only the EDR subsystem but across the entire Crew Module. This paper will present an overview of how the EDR subsystem was managed and compare it to an Agile approach to managing projects. The paper will further provide a recommended approach to future Agile-like hardware development that incorporates lessons learned from the EDR experience.

Agile↗
NASA NTRSDate not supplied

Comparison of Surface Pressure Fluctuations from Flight and Wind Tunnel Tests on the Orion Multi-Purpose Crew Vehicle

Transonic and supersonic wind-tunnel test of scaled-models are used to predict the surface pressure fluctuations on aerospace vehicles. An outstanding question is how good are such tests? The present paper attempts to answer this question for the Multi-Purpose Crew Vehicle by comparing data from the Ascent Abort-2 (AA2) flight test with those measured in two different scaled-model wind tunnel tests (WTT) 51AS and 134AS. A sensor by sensor and a Mach by Mach comparisons of spectra of surface pressure fluctuations are presented for nominal ascent part of flight. Spectra measured over a large part of the vehicle surface were found to be dominated by the wake vortices shed from the four Abort Motor nozzles situated on the upper part of the Launch Abort System. It was found that the shapes of the scaled-up spectra from WTTs were very close to those measured in the flight, but the levels, for the most part, were found to be lower than the flight data. The highest differences were from the regions of complex flows where wakes from the adjacent nozzles interacted with the free-stream flow. There the WTT predicted levels were consistently 2dB to 6dB lower than the flight data, across all spectral bands. Another region of significant under-prediction was the local separated flow region at the Fillet-Ogive junction. The accuracy of the sharp spectral peaks from regions along a nozzle axis was found to be dependent on the fidelity of the model. The model in the 51AS WTT used a simplified contour, which resulted in a large under prediction of the spectral peak by 1dB to 10dB. A limited number of data from 134AS, where the model accurately captured all features of the nozzles of the flight vehicle, however; showed that the under prediction was lower: 1-2dB. The fluctuation spectra on the large protuberance of the Umbilical Cover was found to be reasonably well-predicted by 134AS WTT, which meticulously reproduced a scaled-down shape of this protuberance. Such information will help to determine the margins to be applied to wind-tunnel data to create flight environments.

MPCV↗
NASA NTRSDate not supplied

ARRISTOTLE Simulation Demo

NASA’s Katherine Johnson Independent Verification and Validation (NASA IV&V) Jon McBride Software Testing and Research (JSTAR) laboratory has developed the Advanced Risk Reduction Integrated Software Test and Operations Tri-program Lightweight Environment (ARRISTOTLE). ARRISTOTLE is a digital twin of NASA’s Artemis mission. ARRISTOLE executes the true SLS and Orion flight binaries integrated on a single laptop computer. This demo will showcase the execution of the full Artemis liftoff. Once airborne, an inflight anomaly will be injected, resulting in Orion detaching from the booster. The Launch Abort System (LAS) will safely bring Orion back to earth. The Unity game engine is used to visualize the flyout as flight software executes.

emulation↗
NASA NTRS2014

Application of Fault Management Theory to the Quantitative Selection of a Launch Vehicle Abort Trigger Suite

The theory of System Health Management (SHM) and of its operational subset Fault Management (FM) states that FM is implemented as a "meta" control loop, known as an FM Control Loop (FMCL). The FMCL detects that all or part of a system is now failed, or in the future will fail (that is, cannot be controlled within acceptable limits to achieve its objectives), and takes a control action (a response) to return the system to a controllable state. In terms of control theory, the effectiveness of each FMCL is estimated based on its ability to correctly estimate the system state, and on the speed of its response to the current or impending failure effects. This paper describes how this theory has been successfully applied on the National Aeronautics and Space Administration's (NASA) Space Launch System (SLS) Program to quantitatively estimate the effectiveness of proposed abort triggers so as to select the most effective suite to protect the astronauts from catastrophic failure of the SLS. The premise behind this process is to be able to quantitatively provide the value versus risk trade‐off for any given abort trigger, allowing decision makers to make more informed decisions. All current and planned crewed launch vehicles have some form of vehicle health management system integrated with an emergency launch abort system to ensure crew safety. While the design can vary, the underlying principle is the same: detect imminent catastrophic vehicle failure, initiate launch abort, and extract the crew to safety. Abort triggers are the detection mechanisms that identify that a catastrophic launch vehicle failure is occurring or is imminent and cause the initiation of a notification to the crew vehicle that the escape system must be activated. While ensuring that the abort triggers provide this function, designers must also ensure that the abort triggers do not signal that a catastrophic failure is imminent when in fact the launch vehicle can successfully achieve orbit. That is, the abort triggers must have low false negative rates to be sure that real crew‐threatening failures are detected, and also low false positive rates to ensure that the crew does not abort from non‐crew‐threatening launch vehicle behaviors. The analysis process described in this paper is a compilation of over six years of lessons learned and refinements from experiences developing abort triggers for NASA's Constellation Program (Ares I Project) and the SLS Program, as well as the simultaneous development of SHM/FM theory. The paper will describe the abort analysis concepts and process, developed in conjunction with SLS Safety and Mission Assurance (S&MA) to define a common set of mission phase, failure scenario, and Loss of Mission Environment (LOME) combinations upon which the SLS Loss of Mission (LOM) Probabilistic Risk Assessment (PRA) models are built. This abort analysis also requires strong coordination with the Multi‐Purpose Crew Vehicle (MPCV) and SLS Structures and Environments (STE) to formulate a series of abortability tables that encapsulate explosion dynamics over the ascent mission phase. The design and assessment of abort conditions and triggers to estimate their Loss of Crew (LOC) Benefits also requires in‐depth integration with other groups, including Avionics, Guidance, Navigation and Control(GN&C), the Crew Office, Mission Operations, and Ground Systems. The outputs of this analysis are a critical input to SLS S&MA's LOC PRA models. The process described here may well be the first full quantitative application of SHM/FM theory to the selection of a sensor suite for any aerospace system.

Lo, Yunnhon↗
NASA NTRS2008

2007 Research and Engineering Annual Report

Selected research and technology activities at NASA Dryden Flight Research Center are summarized. These following activities exemplify the Center's varied and productive research efforts: Developing a Requirements Development Guide for an Automatic Ground Collision Avoidance System; Digital Terrain Data Compression and Rendering for Automatic Ground Collision Avoidance Systems; Nonlinear Flutter/Limit Cycle Oscillations Prediction Tool; Nonlinear System Identification Using Orthonormal Bases: Application to Aeroelastic/Aeroservoelastic Systems; Critical Aerodynamic Flow Feature Indicators: Towards Application with the Aerostructures Test Wing; Multidisciplinary Design, Analysis, and Optimization Tool Development Using a Genetic Algorithm; Structural Model Tuning Capability in an Object-Oriented Multidisciplinary Design, Analysis, and Optimization Tool; Extension of Ko Straight-Beam Displacement Theory to the Deformed Shape Predictions of Curved Structures; F-15B with Phoenix Missile and Pylon Assembly--Drag Force Estimation; Mass Property Testing of Phoenix Missile Hypersonic Testbed Hardware; ARMD Hypersonics Project Materials and Structures: Testing of Scramjet Thermal Protection System Concepts; High-Temperature Modal Survey of the Ruddervator Subcomponent Test Article; ARMD Hypersonics Project Materials and Structures: C/SiC Ruddervator Subcomponent Test and Analysis Task; Ground Vibration Testing and Model Correlation of the Phoenix Missile Hypersonic Testbed; Phoenix Missile Hypersonic Testbed: Performance Design and Analysis; Crew Exploration Vehicle Launch Abort System-Pad Abort-1 (PA-1) Flight Test; Testing the Orion (Crew Exploration Vehicle) Launch Abort System-Ascent Abort-1 (AA-1) Flight Test; SOFIA Flight-Test Flutter Prediction Methodology; SOFIA Closed-Door Aerodynamic Analyses; SOFIA Handling Qualities Evaluation for Closed-Door Operations; C-17 Support of IRAC Engine Model Development; Current Capabilities and Future Upgrade Plans of the C-17 Data Rack; Intelligent Data Mining Capabilities as Applied to Integrated Vehicle Health Management; STARS Flight Demonstration No. 2 IP Data Formatter; Space-Based Telemetry and Range Safety (STARS) Flight Demonstration No. 2 Range User Flight Test Results; Aerodynamic Effects of the Quiet Spike(tm) on an F-15B Aircraft; F-15 Intelligent Flight Controls-Increased Destabilization Failure; F-15 Integrated Resilient Aircraft Control (IRAC) Improved Adaptive Controller; Aeroelastic Analysis of the Ikhana/Fire Pod System; Ikhana: Western States Fire Missions Utilizing the Ames Research Center Fire Sensor; Ikhana: Fiber-Optic Wing Shape Sensors; Ikhana: ARTS III; SOFIA Closed-Door Flutter Envelope Flight Testing; F-15B Quiet Spike(TM) Aeroservoelastic Flight Test Data Analysis; and UAVSAR Platform Precision Autopilot Flight Results.

Stoliker, Patrick↗
NASA NTRS2013

Launch Vehicle Debris Models and Crew Vehicle Ascent Abort Risk

For manned space launch systems, a reliable abort system is required to reduce the risks associated with a launch vehicle failure during ascent. Understanding the risks associated with failure environments can be achieved through the use of physics-based models of these environments. Debris fields due to destruction of the launch vehicle is one such environment. To better analyze the risk posed by debris, a physics-based model for generating launch vehicle debris catalogs has been developed. The model predicts the mass distribution of the debris field based on formulae developed from analysis of explosions. Imparted velocity distributions are computed using a shock-physics code to model the explosions within the launch vehicle. A comparison of the debris catalog with an existing catalog for the Shuttle external tank show good comparison in the debris characteristics and the predicted debris strike probability. The model is used to analyze the effects of number of debris pieces and velocity distributions on the strike probability and risk.

Gee, Ken↗
NASA NTRS1974

On thermal stress failure of the SNAP-19A RTG heat shield

Results of a study on thermal stress problems in an amorphous graphite heat shield that is part of the launch-abort protect system for the SNAP-19A radio-isotope thermoelectric generators (RTG) that will be used on the Viking Mars Lander are presended. The first result is from a thermal stress analysis of a full-scale RTG heat source that failed to survive a suborbital entry flight test, possibly due to thermal stress failure. It was calculated that the maximum stress in the heat shield was only 50 percent of the ultimate strength of the material. To provide information on the stress failure criterion used for this calculation, some heat shield specimens were fractured under abort entry conditions in a plasma arc facility. It was found that in regions free of stress concentrations the POCO graphite heat shield material did fracture when the local stress reached the ultimate uniaxial stress of the material.

Pitts, W. C.↗
NASA NTRS2011

Error Estimate of the Ares I Vehicle Longitudinal Aerodynamic Characteristics Based on Turbulent Navier-Stokes Analysis

Numerical predictions of the longitudinal aerodynamic characteristics for the Ares I class of vehicles, along with the associated error estimate derived from an iterative convergence grid refinement, are presented. Computational results are based on the unstructured grid, Reynolds-averaged Navier-Stokes flow solver USM3D, with an assumption that the flow is fully turbulent over the entire vehicle. This effort was designed to complement the prior computational activities conducted over the past five years in support of the Ares I Project with the emphasis on the vehicle s last design cycle designated as the A106 configuration. Due to a lack of flight data for this particular design s outer mold line, the initial vehicle s aerodynamic predictions and the associated error estimates were first assessed and validated against the available experimental data at representative wind tunnel flow conditions pertinent to the ascent phase of the trajectory without including any propulsion effects. Subsequently, the established procedures were then applied to obtain the longitudinal aerodynamic predictions at the selected flight flow conditions. Sample computed results and the correlations with the experimental measurements are presented. In addition, the present analysis includes the relevant data to highlight the balance between the prediction accuracy against the grid size and, thus, the corresponding computer resource requirements for the computations at both wind tunnel and flight flow conditions. NOTE: Some details have been removed from selected plots and figures in compliance with the sensitive but unclassified (SBU) restrictions. However, the content still conveys the merits of the technical approach and the relevant results.

Aerodynamic characteristics↗
NASA NTRS2011

Gain Scheduling for the Orion Launch Abort Vehicle Controller

One of NASAs challenges for the Orion vehicle is the control system design for the Launch Abort Vehicle (LAV), which is required to abort safely at any time during the atmospheric ascent portion of ight. The focus of this paper is the gain design and scheduling process for a controller that covers the wide range of vehicle configurations and flight conditions experienced during the full envelope of potential abort trajectories from the pad to exo-atmospheric flight. Several factors are taken into account in the automation process for tuning the gains including the abort effectors, the environmental changes and the autopilot modes. Gain scheduling is accomplished using a linear quadratic regulator (LQR) approach for the decoupled, simplified linear model throughout the operational envelope in time, altitude and Mach number. The derived gains are then implemented into the full linear model for controller requirement validation. Finally, the gains are tested and evaluated in a non-linear simulation using the vehicles ight software to ensure performance requirements are met. An overview of the LAV controller design and a description of the linear plant models are presented. Examples of the most significant challenges with the automation of the gain tuning process are then discussed. In conclusion, the paper will consider the lessons learned through out the process, especially in regards to automation, and examine the usefulness of the gain scheduling tool and process developed as applicable to non-Orion vehicles.

McNamara, Sara J.↗
NASA NTRS1994

Optimal control theory determination of feasible return-to-launch-site aborts for the HL-20 Personnel Launch System vehicle

The personnel launch system (PLS) being studied by NASA is a system to complement the space shuttle and provide alternative access to space. The PLS consists of a manned spacecraft launched by an expendable launch vehicle (ELV). A candidate for the manned spacecraft is the HL-20 lifting body. In the event of an ELV malfunction during the initial portion of the ascent trajectory, the HL-20 will separate from the rocket and perform an unpowered return to launch site (RTLS) abort. This work details an investigation, using optimal control theory, of the RTLS abort scenario. The objective of the optimization was to maximize final altitude. With final altitude as the cost function, the feasibility of an RTLS abort at different times during the ascent was determined. The method of differential inclusions was used to determine the optimal state trajectories, and the optimal controls were then calculated from the optimal states and state rates.

Dutton, Kevin E.↗
NASA NTRS2010

Pitch Guidance Optimization for the Orion Abort Flight Tests

The National Aeronautics and Space Administration created the Constellation program to develop the next generation of manned space vehicles and launch vehicles. The Orion abort system is initiated in the event of an unsafe condition during launch. The system has a controller gains schedule that can be tuned to reduce the attitude errors between the simulated Orion abort trajectories and the guidance trajectory. A program was created that uses the method of steepest descent to tune the pitch gains schedule by an automated procedure. The gains schedule optimization was applied to three potential abort scenarios; each scenario tested using the optimized gains schedule resulted in reduced attitude errors when compared to the Orion production gains schedule.

Stillwater, Ryan Allanque↗
NASA NTRS1962

Some Abort Techniques and Procedures for Manned Spacecraft

This paper is concerned with our present state of knowledge on the procedures and effectiveness of aborts from manned orbital and lunar missions. By abort is meant a deliberate or unintentional termination of the primary mission followed by an expedient return to earth of the payload (spacecraft and crew). A deliberate abort may be initiated if a critical component failed and thus impaired the probability of mission success or the crew's safety. Examples of this kind of abort are failure of the launch guidance system or the oxygen and cabin pressure system. Also, an unintentional abort may occur during the launch phase due to the complete or partial failure of one of the launch-vehicle stages to operate. For each mission every conceivable set of circumstances must be considered and evaluated to see if an abort of the mission is called for and to determine what sequence of events should occur to bring the spacecraft and crew safely back to earth with the highest probability of success. Factors which must be considered are: how to specify and sense an abort condition, how much fuel should be put onboard the vehicle for abort purposes, what size and kind of rocket engines are best suited for each mission, and what compromise is incurred due to other mission requirements? If an abort occurs, the optimum time of application as well as the magnitude and direction of the velocity changes must be determined beforehand and the crew must be clearly informed of what action is required or what the situation is so that they can decide the proper action.

Maneuver↗
NASA NTRS1993

Optimal return-to-launchsite abort trajectories for an HL-20 Personnel Launch System vehicle

The Personnel Launch System (PLS) being studied by NASA is a system to complement the Space Shuttle and provide alternative access to space. The PLS consists of a manned spacecraft launched by an expendable launch vehicle (ELV). A candidate for the manned spacecraft is the HL-20 lifting body. In the event of an ELV malfunction during the initial portion of the ascent trajectory, the HL-20 will separate from the rocket and perform an unpowered return-to-launchsite (RTLS) abort. This paper describes an investigation of the RTLS abort scenario using optimal control theory. The objective of the abort trajectory is to maximize final altitude at a point near the runway. The assumption is then made that there exists a control history to steer the vehicle to any final altitude lower than the final optimal altitude. With this selection of cost function, and with this assumption, the feasibility of an RTLS abort at different times along the ascent trajectory can be determined. The method of differential inclusions, which allows the determination of optimal states and eliminates the need for determining the optimal controls, is used to determine the optimal trajectories.

Dutton, Kevin E.↗
NASA NTRS2010

Sensitivity Analysis of Launch Vehicle Debris Risk Model

As part of an analysis of the loss of crew risk associated with an ascent abort system for a manned launch vehicle, a model was developed to predict the impact risk of the debris resulting from an explosion of the launch vehicle on the crew module. The model consisted of a debris catalog describing the number, size and imparted velocity of each piece of debris, a method to compute the trajectories of the debris and a method to calculate the impact risk given the abort trajectory of the crew module. The model provided a point estimate of the strike probability as a function of the debris catalog, the time of abort and the delay time between the abort and destruction of the launch vehicle. A study was conducted to determine the sensitivity of the strike probability to the various model input parameters and to develop a response surface model for use in the sensitivity analysis of the overall ascent abort risk model. The results of the sensitivity analysis and the response surface model are presented in this paper.

Gee, Ken↗
NASA NTRS1989

Summary of miscellaneous hazard environments for hypothetical Space Shuttle and Titan IV launch abort accidents

The various analyses described here were aimed at obtaining a more comprehensive understanding and definition of the environments in the vicinity of the Radioisotope Thermal Generator (RTG) during certain Space Transportation System (STS) and Titan IV launch abort accidents. Addressed here are a number of issues covering explosion environments and General Purpose Heat Source Radioisotope Thermoelectric Generator (GPHS-RTG) responses to those environments.

Eck, M.↗