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

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NASA NTRS2001

A Space Based Internet Protocol System for Sub-Orbital Tracking and Control

Personnel from the Goddard Space Flight Center Wallops Flight Facility (GSFC/WFF) in Virginia are responsible for the overall management of the NASA Sounding Rocket Program. Payloads are generally in support of NASA's Space Science Enterprise's missions and return a variety of scientific data as well as providing a reasonably economical means of conducting engineering tests for instruments and devices used on satellites and other spacecraft. The fifteen types of sounding rockets used by NASA can carry payloads of various weights to altitudes from 50 km to more than 1,300 km. Launch activities are conducted not only from established missile ranges, but also from remote locations worldwide requiring mobile tracking and command equipment to be transported and set up at considerable expense. The advent of low earth orbit (LEO) commercial communications satellites provides an opportunity to dramatically reduce tracking and control costs of launch vehicles and Unpiloted Aerial Vehicles (UAVs) by reducing or eliminating this ground infrastructure. Additionally, since data transmission is by packetized Internet Protocol (IP), data can be received and commands initiated from practically any location. A low cost Commercial Off The Shelf (COTS) system is currently under development for sounding rockets which also has application to UAVs and scientific balloons. Due to relatively low data rate (9600 baud) currently available, the system will first be used to provide GPS data for tracking and vehicle recovery. Range safety requirements for launch vehicles usually stipulate at least two independent tracking sources. Most sounding rockets flown by NASA now carry GPS receivers that output position data via the payload telemetry system to the ground station. The Flight Modem can be configured as a completely separate link thereby eliminating requirement for tracking radar. The system architecture which integrates antennas, GPS receiver, commercial satellite packet data modem, and a single board computer with custom software is described along with the technical challenges and the plan for their resolution. These include antenna development, high Doppler rates, reliability, environmental ruggedness, hand over between satellites and data security. An aggressive test plan is included which in addition to environmental testing measures bit error rate, latency and antenna patterns. Actual flight tests are planned for the near future on aircraft, long duration balloons and sounding rockets and these results as well as the current status of the project are reported.

Bull, Barton↗
NASA NTRS2000

Ground Data System Risk Mitigation Techniques for Faster, Better, Cheaper Missions

With the advent of faster, cheaper, and better missions, NASA Projects acknowledged that a higher level of risk was inherent and accepted with this approach. It was incumbent however upon each component of the Project whether spacecraft, payload, launch vehicle, or ground data system to ensure that the mission would nevertheless be an unqualified success. The Small Explorer (SMEX) program's ground data system (GDS) team developed risk mitigation techniques to achieve these goals starting in 1989. These techniques have evolved through the SMEX series of missions and are practiced today under the Triana program. These techniques are: (1) Mission Team Organization--empowerment of a closeknit ground data system team comprising system engineering, software engineering, testing, and flight operations personnel; (2) Common Spacecraft Test and Operational Control System--utilization of the pre-launch spacecraft integration system as the post-launch ground data system on-orbit command and control system; (3) Utilization of operations personnel in pre-launch testing--making the flight operations team an integrated member of the spacecraft testing activities at the beginning of the spacecraft fabrication phase; (4) Consolidated Test Team--combined system, mission readiness and operations testing to optimize test opportunities with the ground system and spacecraft; and (5). Reuse of Spacecraft, Systems and People--reuse of people, software and on-orbit spacecraft throughout the SMEX mission series. The SMEX ground system development approach for faster, cheaper, better missions has been very successful. This paper will discuss these risk management techniques in the areas of ground data system design, implementation, test, and operational readiness.

Catena, John J.↗
NASA NTRS2001

A Space Based Internet Protocol System for Launch Vehicle Tracking and Control

Personnel from the Goddard Space Flight Center Wallops Flight Facility (GSFC/WFF) in Virginia are responsible for the overall management of the NASA Sounding Rocket and Scientific Balloon Programs. Payloads are generally in support of NASA's Space Science Enterprise's missions and return a variety of scientific data as well as providing a reasonably economical means of conducting engineering tests for instruments and devices used on satellites and other spacecraft. Sounding rockets used by NASA can carry payloads of various weights to altitudes from 50 km to more than 1,300 km. Scientific balloons can carry a payload weighing as much as 3,630 Kg to an altitude of 42 km. Launch activities for both are conducted not only from established ranges, but also from remote locations worldwide requiring mobile tracking and command equipment to be transported and set up at considerable expense. The advent of low earth orbit (LEO) commercial communications satellites provides an opportunity to dramatically reduce tracking and control costs of these launch vehicles and Unpiloted Aerial Vehicles (UAVs) by reducing or eliminating this ground infrastructure. Additionally, since data transmission is by packetized Internet Protocol (IP), data can be received and commands initiated from practically any location. A low cost Commercial Off The Shelf (COTS) system is currently under development for sounding rockets that also has application to UAVs and scientific balloons. Due to relatively low data rate (9600 baud) currently available, the system will first be used to provide GPS data for tracking and vehicle recovery. Range safety requirements for launch vehicles usually stipulate at least two independent tracking sources. Most sounding rockets flown by NASA now carry GP~ receivers that output position data via the payload telemetry system to the ground station. The Flight Modem can be configured as a completely separate link thereby eliminating the requirement for tracking radar. The system architecture that integrates antennas, GPS receiver, commercial satellite packet data modem, and a single board computer with custom software is described along with the technical challenges and the plan for their resolution. These include antenna development, high Doppler rates, reliability, environmental ruggedness, hand over between satellites, and data security. An aggressive test plan is included which, in addition to environmental testing, measures bit error rate, latency and antenna patterns. Actual launches on a sounding rocket and various aircraft flights have taken place. Flight tests are planned for the near future on aircraft, long duration balloons and sounding rockets. These results, as well as the current status of the project, are reported.

Bull, Barton↗
NASA NTRS2001

Data Synchronization Discrepancies in a Formation Flight Control System

Aircraft hardware-in-the-loop simulation is an invaluable tool to flight test engineers; it reveals design and implementation flaws while operating in a controlled environment. Engineers, however, must always be skeptical of the results and analyze them within their proper context. Engineers must carefully ascertain whether an anomaly that occurs in the simulation will also occur in flight. This report presents a chronology illustrating how misleading simulation timing problems led to the implementation of an overly complex position data synchronization guidance algorithm in place of a simpler one. The report illustrates problems caused by the complex algorithm and how the simpler algorithm was chosen in the end. Brief descriptions of the project objectives, approach, and simulation are presented. The misleading simulation results and the conclusions then drawn are presented. The complex and simple guidance algorithms are presented with flight data illustrating their relative success.

Ryan, Jack↗
NASA NTRS2001

Thermal Analysis of the MC1 Engine Turbopump

The MC1 Engine turbopump supplied the propellants to the main injector. The turbopump consisted of four parts; lox pump, interpropellant seal package (IPS), RP pump and turbine. The thermal analysis was divided into two 2D finite element models; Housing or stationary parts and rotor or rotating parts. Both models were analyzed at the same boundary conditions using SINDA. The housing model consisted of, lox pump housing, ips housing, RP housing, turbine inlet housing, turbine housing, exit guide vane, heat shield and both bearing outer races. The rotor model consisted of the lox impeller; lox end bearing and id race, RP impeller, and RP bearing and id race, shaft and turbine disk. The objectives of the analysis were to: (1) verified the original design and recommend modifications to it, (2) submitted a thermal environment to support the structural analysis, (3) support the component and engine test program. and (4) to support the X34 vehicle program.

Roman, Jose↗
NASA NTRS2001

KC-135 and Other Microgravity Simulations

This document represents a summary of medical and scientific evaluations conducted aboard the KC-135 from January to June 15, 2001. Included is a general overview of KC-135 activities manifested and coordinated by the Human Adaptation and Countermeasures Office. A collection of brief reports that describes tests conducted aboard the KC-135 follows the overview. Principal investigators and test engineers contributed significantly to the content of the report describing their particular experiment or hardware evaluation. Although this document follows general guidelines, each report format may vary to accommodate differences in experiment design and procedures. This document concludes with an appendix that provides background information concerning the KC-135 and the Reduced-Gravity Program.

Skinner, Noel C.↗
NASA NTRS1998

Prototyping the Future

Advanced Ceramics Research (ACR) of Tucson, Arizona, researches transforming scientific concepts into technological achievement. Through the SBIR (Small Business Innovative Research) program, ACR developed a high pressure and temperature fused deposition system, a prototyping system that is known as extrusion freeform fabrication. This system is useful in manufacturing prosthetics. ACR also developed a three-dimensional rapid prototyping process in which physical models are quickly created directly from computer generated models. Marshall Space Flight Center also contracted ACR to fabricate a set of ceramic engines to be appraised for a solar thermal rocket engine test program.

Source record↗
NASA NTRS2002

Silicon Lightweight Mirrors (SLMS) for Ultraviolet and Extreme Ultraviolet Imaging Mirrors

Subtopic 01-S1.06 requires mirrors with a diameter of 0.5-2.4 meters, areal density less than 20 kg/sq m, a figure specification of 0.02-0.005 waves root mean square (rms) at 633 nanometers, a surface roughness 0.5-1 nanometers rms, and a midfrequency error of 1.0-2.5 nanometers rms for use in the infrared (IR) to extreme ultra violet (EUV) waveband. Schafer's Phase II objective is to use Silicon Lightweight Mirrors (SLMS), a novel, all-silicon, foam-core, lightweight mirror technology, to build three imaging mirrors for the Next Generation Space Telescope Near Infrared Camera (NIRCam) Engineering Test Unit: M0 (a flat), M2 (a concave sphere) and M3R (an oblate spheroid). The surface figure error specification for the NIRCam imaging mirrors is 8 nanometers rms (0.013 waves rms at 633 nanometers), equivalent to that required for ultraviolet (UV) and EUV mirrors, and this figure must be maintained at the 35 K operational temperature of NGST. The surface roughness required is 30 A rms since NIRCam operates in the visible to infrared (VIS/IR) (0.65-5 microns). We will produce mounts for mirrors M2 and M3R using the complementary thermally matched C/SiC material demonstrated by Schafer under another NASA SBIR, NAS8-98137.

Goodman, W. A.↗
NASA NTRS2002

Micromechanics Based Design/Analysis Codes for Advanced Composites

Advanced high temperature Ceramic Matrix Composites (CMC) hold an enormous potential for use in aero and space related applications specifically for propulsion system components. Consequently, this has led to a multitude of research activities pertaining to fabrication, testing and modeling of these materials. The efforts directed at the development of ceramic matrix composites have focused primarily on improving the properties of the constituents as individual phases. It has, however, become increasingly clear that for CMC to be successfully employed in high temperature applications, research and development efforts should also focus on optimizing the synergistic performance of the constituent phases within the as-produced microstructure of the complex shaped CMC part. Despite their attractive features, the introduction of these materials in a wide spectrum of applications has been excruciatingly slow. The reasons are the high costs associated with the manufacturing and a complete experimental testing and characterization of these materials. Often designers/analysts do not have a consistent set of necessary properties and design allowables to be able to confidently design and analyze structural components made from these composites. Furthermore, the anisotropy of these materials accentuates the burden both on the test engineers and the designers by requiring a vastly increased amount of data/characterization compared to conventional materials.

Mital, Subodh K.↗
NASA NTRS2002

COBRA Main Engine Project

The COBRA (CO-Optimized Booster for Reusable Applications) project include the following: 1. COBRA main engine project team. 2. COBRA and RLX cycles selected. 3. COBRA proto-type engine approach enables mission success. 4. COBRA provides quick, low cost demo of cycle and technologies. 5. COBRA cycle I risk reduction supports. 6. Achieving engine safety. 6. RLX cycle I risk reduction supports. 7. Flight qualification. 9. Life extension engine testing.

Snoddy, Jim↗
NASA NTRS2002

Thermal Analysis of the MCI Engine Turbopump

The MCI Engine turbopump supplied the propellants to the main injector. The turbopump consisted of four parts; lox pump, interpropellant seal package (IPS), RP pump and turbine. The thermal analysis was divided into two 2D finite element models; Housing or stationary parts and rotor or rotating parts. Both models were analyzed at the same boundary conditions using SINDA. The housing model consisted of; lox pump housing, ips housing, RP housing, turbine inlet housing, turbine housing, exit guide vane, heat shield and both bearing outer races. The rotor model consisted of the lox impeller; lox end bearing and id race, RP impeller, and RP bearing and id race, shaft and turbine disk. The objectives of the analysis were to (1) verified the original design and recommend modifications to it, (2) submitted a thermal environment to support the structural analysis, (3) support the component and engine test program and (4) to support the X34 vehicle program.

Roman, Jose↗
NASA NTRS2003

Base-Bleed Effect on X-33 Aerospike Plume Induced Base-Heating Environment During Power-Pack Out

A computational heat transfer methodology was developed to study the dual-engine linear aerospike plume induced base-heating environment during one power-pack out, in ascent flight. One power-pack out results in reduction of power levels for both engines. That, in turn, reduces the amount of base-bleed and changes the distribution of base-bleed on the two pillows. Hence, the concern of increased base-heating during power-pack out. The thermo-flowfield of the entire vehicle was computed. The computational methodology for the convective heating is based on a three-dimensional, finite-volume, viscous, chemically reacting, and pressure-based computational fluid dynamics formulation. The computational methodology for the radiative heating is based on a three-dimensional, finite-volume, and spectral-line-based weighted-sum-of-gray-gases absorption computational radiation heat transfer formulation. A separate radiation model was used for diagnostic purposes. The computational methodology was systematically benchmarked. In this study, near-base radiative heat fluxes were computed and they compared well with those measured from an installed linear aerospike engine tests. The base-heating environment of 18 trajectory points selected from three power-pack out ascent scenarios was computed and is presented here. The power-pack out condition has the most impact on convective base-heating when it happens early in flight. The some of its impact comes from the asymmetric and reduced base-bleed.

Wang, Tee-See↗
NASA NTRS2003

RSRM and ETM03 Internal Flow Simulations and Comparisons

ETM03 (Engineering Test Motor-03) is an extended length RSRM (Reusable Solid Rocket Motor) designed to increase motor performance and create more severe internal environments compared with the standard four-segment RSRM motor configuration. This is achieved primarily through three unique design features. First is the incorporation of an additional RSRM center segment, second is a slight increase in throat diameter, and third is the use of an Extended Aft Exit Cone (EAEC). As a result of these design features, parameters such as web time, action time, head end pressure, web time average pressure, maximum thrust, mass flow rate, centerline Mach number, pressure and thrust integrals have all increased compared with nominal RSRM values. In some cases these increases are substantial. The primary objective of the ETM03 test program is to provide a platform for RSRM component margin testing. Test results will not only provide direct data concerning component performance under more adverse conditions, but serve as a second design data point for developing, validating and enhancing component analytical modeling techniques. To help component designers assess how the changes in motor environment will affect performance, internal flow simulations for both the nominal RSRM and ETM03 motor designs were completed to obtain comparisons of aero-thermal boundary conditions and system loads. Full geometries for both motors were characterized with two-dimensional axi-symmetric models at burn times of 1, 20, 54, 67 and 80-seconds. A sixth set considered burn times of 110 and 117-seconds for RSRM and ETM03, respectively. The simulations were performed using the computational fluid dynamics (CFD) commercial code FLUENT (trademark). Of particular interest were any differences between the two motor environments that could lead to a significant increase in system loads, or in internal insulation and/or nozzle component charring and erosion in ETM03 compared with RSRM. Based on these comparative analyses conducted in this study, the objective of ETM03 will be achieved by providing a more adverse operating environment for motor components than the nominal RSRM environment. For example: Higher chamber pressure drop in ETM03 than in RSRM; higher centerline Mach numbers approaching the nozzle in ETM03 than in RSRM; higher heat transfer rates for the internal insulation and nozzle components in ETM03 than in RSRM; and higher levels of droplet impingement and slag accumulation in ETM03 than in the RSRM.

Ahmad, R. A.↗
NASA NTRS2001

Facility Monitoring: A Qualitative Theory for Sensor Fusion

Data fusion and sensor management approaches have largely been implemented with centralized and hierarchical architectures. Numerical and statistical methods are the most common data fusion methods found in these systems. Given the proliferation and low cost of processing power, there is now an emphasis on designing distributed and decentralized systems. These systems use analytical/quantitative techniques or qualitative reasoning methods for date fusion.Based on other work by the author, a sensor may be treated as a highly autonomous (decentralized) unit. Each highly autonomous sensor (HAS) is capable of extracting qualitative behaviours from its data. For example, it detects spikes, disturbances, noise levels, off-limit excursions, step changes, drift, and other typical measured trends. In this context, this paper describes a distributed sensor fusion paradigm and theory where each sensor in the system is a HAS. Hence, given the reach qualitative information from each HAS, a paradigm and formal definitions are given so that sensors and processes can reason and make decisions at the qualitative level. This approach to sensor fusion makes it possible the implementation of intuitive (effective) methods to monitor, diagnose, and compensate processes/systems and their sensors. This paradigm facilitates a balanced distribution of intelligence (code and/or hardware) to the sensor level, the process/system level, and a higher controller level. The primary application of interest is in intelligent health management of rocket engine test stands.

Figueroa, Fernando↗
NASA NTRS2003

Experimental Results for an Annular Aerospike with Differential Throttling

Marshall Space Flight Center funded an internal study on Altitude Compensating Nozzles (ACN) for aerospike engines. The experimental hardware for the engine test is described in this viewgraph presentation, as well as the results of the experiment. The results include spike wall pressures, nozzle efficiency, and side force for four nozzle configurations.

Ruf, Joseph H.↗
NASA NTRS2003

Modeling, Simulation and Control of a Propellant Mixer

This paper addresses some modeling and control issues for a mixing chamber used in rocket engine testing at NASA Stennis Space Center. The mixer must combine high pressure liquid hydrogen (LH2) and gaseous hydrogen (GH2) to produce and output flow that meets certain thermodynamic properties before it is fed into a test article. More precisely, this paper considers that the quantities to be tracked and/or regulated are mixer internal pressure, exit mass flow, and exit temperature. The available control inputs are given by three value positions, namely those of the GH2, LH2 and exit valves. The mixer is modelled by a system of two nonlinear ordinary differential equations having density and internal energy as states. The model must be simple enough to lend itself to subsequent feedback controller design, yet its accuracy must be tested against real data. For this reason, the model includes function calls to thermodynamic property data. Some structural properties of the resulting model that pertain to controller design, such as controllability and uniqueness of the equilibrium point are shown to hold. Validation of the model against real data is also provided. As a first control approach, a small-signal (linear) model is developed based on the nonlinear model and simulated as well. Pulse disturbances are introduced to the valve positions and the quality of the linear model is ascertained by comparing its behavior against the nonlinear model simulations. Valve control strategies that simulate an operator-in-the-loop scenario are then explored demonstrating the need for automatic feedback control. Classical optimal single-output and multi-output Proportional/Integral controllers are designed based on the linear model and applied to the nonlinear model with excellent results to track simultaneous, constant setpoint changes in desired exit flow, exit temperature, and mixer pressure, as well as to reject unmeasurable but bounded additive step perturbations in the valve positions. A feedback linearization controller is designed and used to achieve tracking and regulation of the outputs over an extended range of the variables of interest.

Richter, Hanz↗
NASA NTRS2003

Small Signal Point-to-Point Tracking of a Propellant Mixer

This paper addresses some theoretical modelling and control issues for a mixing chamber used in rocket engine testing at NASA Stennis Space Center. The mixer is responsible for combining high pressure LH2 and GH2 to produce a hydrogen flow that meets certain thermodynamic properties before it is fed into a test article. The desired properties are maintained by precise control of the LH2 and GH2 flows. The mixer is modelled as a general multi-flow lumped volume for single constituent fluids using density and internal energy as states. The set of nonlinear differential equations is modelled in the SIMULINK environment including a table look-up feature of the fluid thermodynamic properties. a small-signal (linear) model is developed based on the nonlinear model and simulated as well. Pulse disturbances are introduced to the valve positions and the quality of the linear model is ascertained by comparing its behavior against the nonlinear model simulations. Valve control strategies that simulate an operator-in-the-loop scenario are then explored demonstrating the need for automatic feedback control. Finally, classical optimal single-output and multi-output Proportional/Integral controllers are designed based on the linear model and applied to the nonlinear model with excellent results to track simultaneous, constant setpoint changes in desired exit flow, exit temperature, and mixer pressure, as well as to reject unmeasurable but bounded additive step perturbations in the valve positions.

Barbieri, Enrique↗
NASA NTRS2002

Improved Electrohydraulic Linear Actuators

A product line of improved electrohydraulic linear actuators has been developed. These actuators are designed especially for use in actuating valves in rocket-engine test facilities. They are also adaptable to similar industrial uses. Advantageous features of the electrohydraulic linear actuators with respect to shortcomings of prior electrohydraulic linear actuators are described.

Hamtil, James↗