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Flush joint coupling using foil jacketed annular cone, backfilled with carbon dioxide, eliminates inherent connection problems of conventional bayonet type joints used for vacuum jacketed assemblies.
A tetrahedral beam that can be compactly stowed, sequentially deployed, and widely manipulated to provide a structurally sound yet highly maneuverable truss structure is comprised of a number of repeating units of tandem tetralhedral sharing common sides. Fixed length battens are jointed into equilateral triangles called batten frames. Apexes of adjacent triangles are interconnected by longerons having a mid-point folding hinge. Joints, comprised of gussets pivotabley connected by links, permit two independent degrees of rotational freedom between joined adjacent batten frames, and provide a stable structure from packaged configuration to complete deployment. The longerons and joints can be actuated in any sequence, independently of one another. The beam is suited to remote actuation. Longerons may be provided with powered mid-point hinges enabling beam erection and packaging under remote control. Providing one or more longerons with powered telescoping segments permits the shape of the beam central axis to be remotely manipulated so that the beam may function as a remote manipulator arm.
Analytical and experimental techniques for the prediction and ground verification of the damped structural dynamics of space structures are developed. The options available for similarity-scaled model testing, including replica and multiple scale approaches, are reviewed. For the case when the distortion of potentially dissipative or nonlinear joints, which would be required in multiple-scale modeling, is impractical, a new type of modeling is introduced, which uses a hybrid of joints at replica scale and connecting elements at a modified multiple scale. The model design requirements for replica, multiple-scale, and hybrid models are developed, and the expected scaling of nonlinear dissipation in joints is derived. A damping prediction scheme is developed that relies on a finite element model of the undamped structure and measurements of the individual joint properties to predict the modal damping of the truss attributable to the joints. A hybrid-scaled model of a segment of the Space Station was built and dynamically tested. The predicted and measured truss damping compared favorably.
Tubular transition joints providing a metallurgically bonded connection between tantalum and 316 stainless steel pipe sections were comparatively evaluated for durability under thermal cycling conditions approximating the operation of a SNAP-8 mercury boiler. Both coextruded and vacuum brazed transition joints of 50mm (2 inch) diameter were tested by thermal cycling 100 times between 730 C and 120 C(1350 F and 250 F) in a high vacuum environment. The twelve evaluated transition joints survived the full test sequence without developing leaks, although liquid penetrant bond line indications eventually developed in all specimens. The brazed transition joints exhibited the best dimensional stability and bond line durability.
Space exploration is dependent on robotic systems that utilize end-effectors to collect samples, probe surfaces, and manipulate objects. These systems can rarely be designed to do all three, forcing engineers to make tradeoffs based on the mission parameters - i.e. should the robotic appendage have a claw, drill, or shovel, and which would be best suited for the mission? Additionally, as more industrial and government entities partake in space exploration, data protection is needed in transit and at rest. To address these challenges, we present a first-of-its- kind robotic linkage that has no wiring between the joints. Instead, quasi-wireless capacitive (QWiC) power transfer is used to send energy over the robot’s chassis without a return wire. This enables the system to be completely modular through the use of single-contact permanent magnet connections, allowing rapid alterations in joint kinematics and/or the changing of end-effectors. For collecting sensor data from the robotic arm and to send remote commands to it, we use a Supervisory Control and Data Acquisition (SCADA) system. Data transmission relies on MQTT and OPC UA communication protocols with encryption. The SCADA server logs and archives sensor data and provides the functionality for authorized users to send remote commands from SCADA client(s) to motors. A SCADA client can be any of the web browsers that connects to a server via a secure communication channel using SSL protocol. Furthermore, as an extra data protection mechanism, we inject noise to the sensor data traffic, which obfuscates the timing of sensor data packets and adds confusion about which data packet represents which motor.
The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is a structural concept that was developed by The Boeing Company to address the complex structural design aspects associated with a pressurized hybrid wing body aircraft configuration. An important design feature required for assembly is the integrally stitched T-cap, which provides connectivity of the corner (orthogonal) joint between adjacent panels. A series of tests were conducted on T-cap test articles, with and without a rod stiffener penetrating the T-cap web, under tension (pull-off) and bending loads. Three designs were tested, including the baseline design used in large-scale test articles. The baseline had only the manufacturing stitch row adjacent to the fillet at the base of the T-cap web. Two new designs added stitching rows to the T-cap web at either 0.5- or 1.0-inch spacing along the height of the web. Testing was conducted at NASA Langley Research Center to determine the behavior of the T-cap region resulting from the applied loading. Results show that stitching arrests the initial delamination failures so that the maximum strength capability exceeds the load at which the initial delaminations develop. However, it was seen that the added web stitching had very little effect on the initial delamination failure load, but actually decreased the initial delamination failure load for tension loading of test articles without a stiffener passing through the web. Additionally, the added web stitching only increased the maximum load capability by between 1% and 12.5%. The presence of the stiffener, however, did increase the initial and maximum loads for both tension and bending loading as compared to the stringerless baseline design. Based on the results of the few samples tested, the additional stitching in the T-cap web showed little advantage over the baseline design in terms of structural failure at the T-cap web/skin junction for the current test articles.
An internally supported, flexible duct joint for use in conducting fluids under relatively high pressures in systems where relatively large deflection angles must be accommodated is presented. The joint includes a flexible tubular bellows and an elongated base disposed within the bellows. The base is connected through radiating struts to the bellows near mid-portion and to each of the opposite end portions of the bellows through a pivotal connecting body. A motion-controlling linkage is provided for linking the connecting bodies, whereby angular displacement of the joint is controlled and uniformity in the instantaneous bend radius of the duct is achieved as deflection is imposed.
This paper overviews the initial results of a new project at the Oak Ridge National Laboratory -- supported via an internal seed funding program -- focused on the development of a novel computational capability, called MAPPER, to support model validation. The MAPPER development aims to eliminate the need for empirical criteria, such as similarity indices, often employed to identify applicable experiments for given application conditions. To achieve that, MAPPER employs an information-theoretic-based approach, based on the Kullback-Leibler (KL) divergence principle, to combine responses of available or to-be-built experiments with application responses of interest using a training set of samples generated using randomized execution of the experiments and the application high fidelity analysis models. These samples are condensed using reduced order modeling techniques in the form of a joint probability distribution function (PDF) connecting each application response of interest with a new effective experimental response. The initial focus of the MAPPER capability will be to support the confirmatory analysis required for criticality safety analysis of storage facilities which require k-eff biases to be known for safe operation. This paper reports some of the initial results obtained with MAPPER as applied to a set of critical experiments for which existing similarity-based methods have been shown to provide inaccurate estimates of the biases.
The Hubble Space Telescope pointing error produced by optical benches mounted on free ball joints is examined. Spacecraft cable connections are assumed to produce translational and rotational damping and restoring forces which act through the optical bench center of mass. The nonlinear dynamics are modeled and then implemented using an existing computer program for simulating the vehicle dynamics and pointing control system algorithm. Results are presented for the test case which indicate acceptable performance.
The NASA Space Station's Space Erectable Radiator System features modular radiator panels with high-capacity tapered artery heat pipes bonded within their aluminum honeycomb structures. Simple, dry aluminum-to-aluminum thermal contact surfaces are used for the connections, thereby requiring no fluid joints; a uniformly distributed clamping force at the radiator panel-to-thermal transport loop interface heat exchange surface yields high thermal contact conductance as well as minimum area and weight for the requisite performance. The design has been optimized for weight and cost.
The Magnetospheric MultiScale (MMS) mission employs a formation of spinning spacecraft with several flexible appendages and thruster-based control. To understand the complex dynamic interaction of thruster actuation, appendage motion, and spin dynamics, each spacecraft is modeled as a tree of rigid bodies connected by spherical or gimballed joints. The method presented facilitates assembling by inspection the exact, nonlinear dynamic equations of motion for a multibody spacecraft suitable for solution by numerical integration. The building block equations are derived by applying Newton's and Euler's equations of motion to an "element" consisting of two bodies and one joint (spherical and gimballed joints are considered separately). Patterns in the "mass" and L'force" matrices guide assembly by inspection of a general N-body tree-topology system. Straightforward linear algebra operations are employed to eliminate extraneous constraint equations, resulting in a minimum-dimension system of equations to solve. This method thus combines a straightforward, easily-extendable, easily-mechanized formulation with an efficient computer implementation.
The Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) is a structural concept that was developed by The Boeing Company to address the complex structural design aspects associated with a pressurized hybrid wing body aircraft configuration. An important design feature required for assembly is the integrally stitched T-cap, which provides connectivity of the corner (orthogonal) joint between adjacent panels. A series of tests were conducted on T-cap test articles, with and without a rod stiffener penetrating the T-cap web, under tension (pull-off) and bending loads. Three designs were tested, including the baseline design used in largescale test articles. The baseline had only the manufacturing stitch row adjacent to the fillet at the base of the T-cap web. Two new designs added stitching rows to the T-cap web at either 0.5- or 1.0-inch spacing along the height of the web. Testing was conducted at NASA Langley Research Center to determine the behavior of the T-cap region resulting from the applied loading. Results show that stitching arrests the initial delamination failures so that the maximum strength capability exceeds the load at which the initial delaminations develop. However, it was seen that the added web stitching had very little effect on the initial delamination failure load, but actually decreased the initial delamination failure load for tension loading of test articles without a stiffener passing through the web. Additionally, the added web stitching only increased the maximum load capability by between 1% and 12.5%. The presence of the stiffener, however, did increase the initial and maximum loads for both tension and bending loading as compared to the stringerless baseline design. Based on the results of the few samples tested, the additional stitching in the T-cap web showed little advantage over the baseline design in terms of structural failure at the T-cap web/skin junction for the current test articles.
Torque driven disconnect maintains connection on a gas supply line until desired parting occurs at a remote location. It consists of a helical plastic tube with a disconnect coupling fitted for an interference condition slip joint, and a rotationally constrained support connected to a gas source.
The increasing demand to improve focusing accuracy and to accommodate higher frequencies in space communications and radio astronomy has created significant challenges for improving the capability of the constituent systems in radio antennas and telescopes. One important system is the radio antenna/telescope backup structure connections. The backup structure is a key element in providing a stable, precise and rigid support for the reflective surface. The ideal connection for these types of structures is rigid and concentric resulting in minimal deformation with stress/strain curves that are linear, repeatable and exhibiting no hysteresis over the entire service load range. Conceivably such a connection could be designed so that the stress/strain curve mimics the stress/strain characteristics of the connecting member in both tension and compression. When this is achieved then such joints can be said to be 'invisible' in the global behavior of the backup structure. At that point, overall reflector deflection becomes more linear and highly predictable. In conjunction with this advantage, optimized backup structure geometries, adaptive reflectors and compensating algorithms can best be applied in producing an instrument of unparalleled performance. This paper introduces Co-Axial Joint (CAJ) technology as the practical and economical means to produce an invisible connection.
T-joints are key structural elements that connect opposing surfaces, thereby providing the load path between flat or curved panels (i.e., upper and lower wing skins) and transverse components (i.e., stiffeners). Due to the low interlaminar strength of polymer matrix composites and their geometrical discontinuities, these joints are vulnerable to pull-off loads. To address these issues, through-thickness reinforcements can be employed to enhance the interlaminar capability of these type of joints. In this study, T-joints were manufactured using through-thickness stitching in dry carbon preforms and cured using the vacuum-assisted resin transfer molding (VARTM) process. Stitched and unstitched T-joints were tested under pull-off loading conditions, and surface strain fields were obtained using a 3D digital image correlation system. The ultimate load, displacement, and absorbed energy of the stitched T-joints were greater than their unstitched counterparts by approximately 16%, 34%, and 58%, respectively. Failure mechanisms were identified by examining fracture surfaces using optical microscopy. Results demonstrate that through-thickness stitching significantly improves the damage tolerance of T-joints, which highlights the effectiveness of stitching to enhance the structural integrity of large aerospace components.
This paper describes work accomplished to predict the service life of a flexure joint design which is a component of a diffuser duct in the A3 Test Stand, an altitude simulation rocket engine test facility at NASA's Stennis Space Center. The duct has two pressure shells separated by cooling water passages and connected by stiffening ribs and flexure joints. Rocket exhaust flows within the duct and heats the inner pressure shell while the outer pressure shell remains at ambient temperature. The flexure joints allow for differential thermal expansion of the inner and outer pressure shells and are subject to in-service loading by this thermal expansion along with water pressure in the cooling water passage, atmospheric pressure outside the duct, near vacuum conditions within the duct, and vibrational loads from operation of the facility and rocket engine. Figure 1 shows a schematic axisymmetric cross section of the diffuser pressure shells and flexure joints with a zoomed in view of the flexure joint. The flexure joints are expected to eventually fail by fatigue cracking leading to leaks from the cooling water passages to the outside. The zoomed in view in Figure 1 indicates where cracking is expected to occur, namely through a weld bead between two plates of SA-516 Grade 70 steel. This weld bead acts as the fulcrum of the flexure joint and it is clear from inspection of the geometry and loading represented in the zoomed in portion of Figure 1 that inherent in the design there is a severe notch formed between the flexure plate, weld bead, and stiffening ring that will be the site of crack initiation and location from which the crack grows to the outer surface of the weld bead.
Networks of intersecting fractures often provide the flow paths through subsurface reservoirs. Assessing network connectivity is challenging because fracture intersections compose a vanishingly small fraction of the network void volume. In this paper, motivated by 3D X-ray imaging of the simplest element of fracture network, that is, two orthogonal fractures, we perform a percolation and finite-size scaling analysis to study the connectivity provided by fracture intersections. The conditions when an intersection enhances connectivity across a sample depend on spatial correlations in the fracture aperture distributions, on the stress state, and on the direction of flow. Here we consider three flow directions: (a) across intersections, (b) parallel to intersections and (c) around corners. For (a), intersections provide minimal enhancement of connectivity because they contribute little additional void area. For (b), intersections increase the probability of a connected path near threshold by enabling 3D connected pathways that are not possible in parallel fractures. Flow around corners, (c), is fundamentally the result of the intersection connecting two fractures in series and spatial correlations are broken around corners, suppressing the connectivity relative to (a). When the connected fractures are stressed equally, a joint percolation threshold emerges that continues to have scale invariance. However, when the fractures are stressed unequally, the system has mixed percolation without clearly defined percolation thresholds. In all cases, percolation probabilities are found to be scale dependent which has important consequences for the connectivity of larger fracture networks composed of the fundamental element studied here.
A rehabilitative device first featured in Spinoff 2003 is not only helping human patients regain the ability to walk, but is now helping our four-legged friends as well. The late James Kerley, a prominent Goddard Space Flight Center researcher, developed cable-compliant mechanisms in the 1980s to enable sounding rocket assemblies and robots to grip or join objects. In cable-compliant joints (CCJs), short segments of cable connect structural elements, allowing for six directions of movement, twisting, alignment, and energy damping. Kerley later worked with Goddard s Wayne Eklund and Allen Crane to incorporate the cable-compliant mechanisms into a walker for human patients to support the pelvis and imitate hip joint movement.