Results for “Qualification Testing” — Page 9

NASA NTRS1999

Benefits of Force Limiting Vibration Testing

Force limited random vibration testing is used at NASA John Glenn Research Center (formerly NASA Lewis Research Center) for qualifying aerospace hardware for flight. The benefit of force limiting testing is that it limits overtesting of flight hardware, by controlling input force and acceleration from the shaker (dual control) to the test article. The purpose of force limiting is to replicate the test article resonant response for the actual flight mounting condition. The force limiting testing technology has been implemented at the Jet Propulsion Laboratory for the past 10 years on various spacecraft testing programs. The Cassini mission to Saturn, most notably, utilized force limiting vibration testing as part of the spacecraft system level vibration testing. NASA John Glenn Research Center is responsible for microgravity combustion and fluid science research on the Shuttle and the International Space Station. Qualification testing of delicate and vibration sensitive science instrumentation is particularly challenging to successfully qualify for flight. In order to facilitate the testing process, force limiting has been implemented to minimize overtesting of flight hardware. This paper will address recent flight camera testing (qualification random vibration and strength testing) for the Combustion Module-2 mission and the impact of Semi-empirical Method force limits.

McNelis, Mark E.↗

NASA NTRSDate not supplied

Novel Test and Analysis Methodology for the Assessment of Joint under Re-entry Environment

Spacecraft thermal protection systems require unique approaches for design verification due to the extreme environments seen during space travel and atmospheric re-entry. In this work, unique considerations for design, analysis, and verification of a tiled heatshield design with material nonlinearity, material property temperature-dependency, material property rate-dependency, and geometric stress concentrations are presented. Such designs require a thorough application of the building block approach to derive appropriate material property datasets, and a novel application of analysis models to aid in the structural verification with testing. The custom application of material rate-dependency in finite element analysis software is presented as a means of leveraging the rate-dependent test data for the material property dataset. Because bonded tile heatshields contain so many design considerations and nonlinearities which often preclude the ability to easily achieve the requisite test factors in qualification testing, a novel sub-element test was developed that amplifies the stress singularity beyond flight conditions. The test achieves an over-test over flight stress conditions. The approach for sub-element coupon design can be extended to other bonded joint designs and can be used in aiding a qualification program.

Pavel Babuska↗

NASA NTRS1983

Application experience with the NASA aircraft interrogation and display system - A ground-support equipment for digital flight systems

The NASA Dryden Flight Research Facility has developed a microprocessor-based, user-programmable, general-purpose aircraft interrogation and display system (AIDS). The hardware and software of this ground-support equipment have been designed to permit diverse applications in support of aircraft digital flight-control systems and simulation facilities. AIDS is often employed to provide engineering-units display of internal digital system parameters during development and qualification testing. Such visibility into the system under test has proved to be a key element in the final qualification testing of aircraft digital flight-control systems. Three first-generation 8-bit units are now in service in support of several research aircraft projects, and user acceptance has been high. A second-generation design, extended AIDS (XAIDS), incorporating multiple 16-bit processors, is now being developed to support the forward swept wing aircraft project (X-29A). This paper outlines the AIDS concept, summarizes AIDS operational experience, and describes the planned XAIDS design and mechanization.

Glover, R. D.↗

NASA NTRS1973

Qualification flight tests of the Viking decelerator system.

The Balloon Launched Decelerator Test (BLDT) series conducted at White Sands Missile Range (WSMR) during July and August of 1972 flight qualified the NASA Viking '75 decelerator system at conditions bracketing those expected for Mars. This paper discusses the decelerator system design requiremnts, compares the test results with prior work, and discusses significant considerations leading to successful qualification in earth's atmosphere. The Viking decelerator system consists of a single-stage mortar-deployed 53-foot nominal diameter disk-gap-band parachute. Full-scale parachutes were deployed behind a full-scale simulated Viking vehicle at Mach numbers from 0.47 to 2.18 and dynamic pressures from 6.9 to 14.6 psf. Analyses show that the system is qualified with sufficient margin to perform successfully for the Viking mission.

Moog, R. D.↗

NASA NTRS1977

Design and development of a structural mode control system

A program was conducted to compile and document some of the existing information about the conceptual design, development, and tests of the B-1 structural mode control system (SMCS) and its impact on ride quality. This report covers the following topics: (1) Rationale of selection of SMCS to meet ride quality criteria versus basic aircraft stiffening. (2) Key considerations in designing an SMCS, including vane geometry, rate and deflection requirements, power required, compensation network design, and fail-safe requirements. (3) Summary of key results of SMCS vane wind tunnel tests. (4) SMCS performance. (5) SMCS design details, including materials, bearings, and actuators. (6) Results of qualification testing of SMCS on the "Iron Bird" flight control simulator, and lab qualification testing of the actuators. (7) Impact of SMCS vanes on engine inlet characteristics from wind tunnel tests.

Source record↗

NASA NTRS1986

Flight control system development and flight test experience with the F-111 mission adaptive wing aircraft

The wing on the NASA F-111 transonic aircraft technology airplane was modified to provide flexible leading and trailing edge flaps. This wing is known as the mission adaptive wing (MAW) because aerodynamic efficiency can be maintained at all speeds. Unlike a conventional wing, the MAW has no spoilers, external flap hinges, or fairings to break the smooth contour. The leading edge flaps and three-segment trailing edge flaps are controlled by a redundant fly-by-wire control system that features a dual digital primary system architecture providing roll and symmetric commands to the MAW control surfaces. A segregated analog backup system is provided in the event of a primary system failure. This paper discusses the design, development, testing, qualification, and flight test experience of the MAW primary and backup flight control systems.

Larson, R. R.↗

NASA NTRS1986

Flight control system development and flight test experience with the F-111 mission adaptive wing aircraft

The wing on the NASA F-111 transonic aircraft technology airplane was modified to provide flexible leading and trailing edge flaps. This wing is known as the mission adaptive wing (MAW) because aerodynamic efficiency can be maintained at all speeds. Unlike a conventional wing, the MAW has no spoilers, external flap hinges, or fairings to break the smooth contour. The leading edge flaps and three-segment trailing edge flaps are controlled by a redundant fly-by-wire control system that features a dual digital primary system architecture providing roll and symmetric commands to the MAW control surfaces. A segregated analog backup system is provided in the event of a primary system failure. This paper discusses the design, development, testing, qualification, and flight test experience of the MAW primary and backup flight control systems.

Larson, R. R.↗

NASA NTRS1993

Characterization of in-flight performance of ion propulsion systems

In-flight measurements of ion propulsion performance, ground test calibrations, and diagnostic performance measurements were reviewed. It was found that accelerometers provided the most accurate in-flight thrust measurements compared with four other methods that were surveyed. An experiment has also demonstrated that pre-flight alignment of the thrust vector was sufficiently accurate so that gimbal adjustments and use of attitude control thrusters were not required to counter disturbance torques caused by thrust vector misalignment. The effects of facility background pressure, facility enhanced charge-exchange reactions, and contamination on ground-based performance measurements are also discussed. Vacuum facility pressures for inert-gas ion thruster life tests and flight qualification tests will have to be less than 2 mPa to ensure accurate performance measurements.

Sovey, James S.↗

NASA NTRS1993

Characterization of in-flight performance of ion propulsion systems

In-flight measurements of ion propulsion performance, ground test calibrations, and diagnostic performance measurements were reviewed. It was found that accelerometers provided the most accurate in-flight thrust measurements compared with four other methods that were surveyed. An experiment has also demonstrated that pre-flight alignment of the thrust vector was sufficiently accurate so that gimbal adjustments and use of attitude control thrusters were not required to counter disturbance torques caused by thrust vector misalignment. The effects of facility background pressure, facility enhanced charge-exchange reactions, and contamination on ground-based performance measurements are also discussed. Vacuum facility pressures for inert-gas ion thruster life tests and flight qualification tests will have to be less than 2 mPa to ensure accurate performance measurements.

Sovey, James S.↗

NASA NTRS2005

Validation of NHB 8060.1C, Test 18 Arc Tracking, September 30, 1991

A test project was conducted to validate Test 18 of NASA Handbook (NHB) 8060.1C and, if necessary, identify and recommend improvements in the procedures or criteria of the test. The NHB 8060.1C, Test 18 test system was modified to produce better discrimination of test results. Changes, and their effects on test results, in the graphite immersion-depth, test timing sequence, and atmospheric conditions were investigated for the wire-insulation constructions tested. Based on the test results, the graphite immersion-depths (between 0.8 mm and 1.6 mm), the timing sequence, and the change in the test conditions from ambient to three environments common in manned spaceflight did not significantly affect test results. The criteria used in Test 18 of NHB 8060.1C was found to be appropriate for qualifying arc-tracking and arc-propagation characteristics of wire-insulation materials, Using the Test 18 criteria, Kapton and ETFE were considered inappropriate for use, while PTFE was considered appropriate. Recommendations from this test project for Test 18 of NHB 8060.1C include changing the experimental setup and configurational tests and performing qualification testing in air rather than in the three environments common in manned spaceflight.

Linley, Larry↗

NASA NTRS2009

Advanced Development Program for a 625 lbf thrust engine for Ares First Stage Roll Control System

NASA's new Ares Launch Vehicle will require twelve thrusters to provide roll control of the vehicle during the first stage firing. All twelve roll control thrusters will be located at the inter-stage segment that separates the solid rocket booster first stage from the second stage. NASA selected a mono propellant hydrazine solution and as a result awarded Aerojet-General a contract in 2007 for an advanced development program for an MR-80- series 625 Ibf vacuum thrust monopropellant hydrazine thruster. This thruster has heritage dating back to the 1976 Viking Landers and most recently for the 2011 Mars Science Laboratory. Prior to the Ares application, the MR-80-series thrusters had been equipped with throttle valves and not typically operated in pulse mode. The primary objective of the advanced development program was to increase the technology readiness level and retire major technical risks for the future flight qualification test program. Aerojet built on their heritage MR-80 rocket engine designs to achieve the design and performance requirements. Significant improvements to cost and lead-time were achieved by applying Design for Manufacturing and Assembly (DFMA) principles. AerojetGeneral has completed Preliminary and Critical Design Reviews, followed by two successful rocket engine development test programs. The test programs included qualification random vibration and firing lite that significantly exceed the flight qualification requirements. This paper discusses the advanced development program and the demonstrated capability of the MR-80C engine. Y;

Dawson, Matt↗

NASA NTRS2018

Measurements of Parachute Dynamics in the World's Largest Wind Tunnel by Stereo Photogrammetry

Between 2012 and 2017, parachutes for four NASA Projects were tested in the 80- by 120-Ft test section of the National Full-Scale Aerodynamic Complex (NFAC) at NASA Ames Research Center. These projects were: (1) Low-Density Supersonic Decelerator (LDSD); (2) Capsule Parachute Assembly System (CPAS, for Orion); (3) Interior Exploration using Seismic Investigations, Geodesy and Heat Transport (InSight, a Mars mission); and (4) Mars 2020. In all tests stereo photogrammetry was used to measure time-dependent positions of features on the canopies. For the LDSD and CPAS tests, where the purpose was to study the trade-off between stability and drag of different parachute designs, the pendulum motion of the canopies about the riser attachment point was measured by calibrated cameras in the diffuser. The CPAS test also included static measurements where the inflated parachutes were pulled to the side by a system of tethers. The Insight tests were structural qualification tests where each canopy was packed in a bag and launched from a mortar. Cameras in the diffuser measured the trajectory of the bag and the stripping of the bag from the canopy. The Mars 2020 test was a workmanship verification test where the canopies were either launched from a mortar or deployed from a sleeve stretched along the tunnel axis. The deployments were recorded from many directions by thirteen high-speed cameras distributed in the diffuser and test section. Photogrammetry was not planned; however, after a tunnel-related accident ended the test prematurely, photogrammetric measurements were bootstrapped from the images to support the accident investigations. This paper describes how the photogrammetry measurements were made in each test and presents typical results.

Schairer, Edward T.↗

NASA NTRS2022

Simulating Mars: Enabling Testing of the Perseverance Rover Sampling and Caching Subsystem on Earth

The development of the Sampling and Caching Subsystem (SCS) on the JPL Perseverance Rover lies at the intersection of testing, robotics, and geology. The SCS team established three primary system test campaigns and venues to aid in the development of SCS through verification and validation testing – Qualification Model Dirty Testing (QMDT) to provide a venue for testing in a Martian environment, Vehicle System Testbed (VSTB) for testing while integrated with the mobility subsystem on Martian-like terrain, and the Flight Software Testbed (FSWTB) for conducting tests using the flight motor controllers and software system on a hexapod which had the ability to simulate rover tilt. Each venue contributed a vital piece to the SCS building blocks. However, the QMDT venue operating within a 10-ft diameter Thermal Vacuum chamber to simulate Martian environment provided a sui generis opportunity to fine tune the entire sampling and caching process while building the team’s knowledge base about rock drillability, system life, and target selection. On Earth, because Martian rocks are not readily available, the development team must utilize geoanalogs to the rocks and regolith on Mars. Geologists on the team helped establish a set of standard rock types to use for Mars missions, like Basalt, Sandstone, Mudstone, Gypsum, and other related geoanalogs. These geoanalogs are characterized with a standard suite of tests for density, compressibility, and other characteristics to categorize potential drillability. This concept of drillability is what links the geoanalogs on Earth to the samples we collect on Mars. With the simulant characteristics defined, these geoanalog rocks are ready to be drilled into as we do on the Martian surface. A key aspect of interacting with the surface on Mars is rock target identification and selection. The Perseverance robotic system uses the on-board cameras, instrumentation, and software to collect enough information to identify potential scientific targets. With the targets identified, SCS can place the Corer and abrade the surface or collect a sample. For a ground test activity like QMDT, the test team did not have all of the camera and instrumentation systems that the rover does, so the team developed ground test equivalents to process a rock, build a target map, and define the target. The team constructed a Rock Scanning Station to build a 3D point cloud of the rock. This point cloud was then processed and evaluated with predefined and programmed criteria in a Target Downselect Tool. A primary output of the Target Downselect Tool is a defined target that can be uploaded directly to the robotic software system to simulate and build the robotic sequences used in tests. With these insights and programmatic definition of targets, the QMDT test team was able to make the same decisions that the Perseverance surface operations team does. In addition, valuable lessons learned from developing the target selection ground tools and using them were implemented into the tools used for surface operations.

Kim, Junggon↗

NASA NTRS2024

Overview of Integrated Random Vibration Testing of the NASA Orion Crew Survival Suit

The launch ascent and abort random vibration environments from NASA’s Orion spacecraft drove the need to test the NASA Orion Crew Survival Suit as an integrated system with exposure to the design levels. In order to properly characterize component responses, a series of integrated tests were designed to incorporate the interaction between a crew member, suit, seat, and the attenuation system. The first Development Test (2017) included human subjects, and was performed with early development seat and suit components, and low level inputs. It provided a baseline for frequency response and behavior of the integrated system. The next two tests, Development Test (2019) and Qualification Test (2020), used manikin surrogates to represent the crew member and increasing levels of component hardware fidelity in order to test to higher input levels. Testing was performed at NASA Johnson Space Center (JSC) and Kennedy Space Center (KSC) Vibration Labs and provided the input levels required to represent the ascent and abort vehicle profiles as well as recorded component response behavior from accelerometer instrumentation and high speed cameras. Inspection of the suit and related components showed that for all seat orientations, and input environments, no damage occurred. Additional pre and post-test checks confirmed the functionality of all suited hardware. Response data of the suited components generally showed heavy attenuation across most of the tested frequency range. Transmissibility plots showed some amplification of components at lower frequency ranges. Overall this series of integrated tests showed that 1) the use of surrogate manikins in the tests were adequate for representing crew in a vibration environment, 2) full vibration levels for ascent and abort were heavily attenuated in the suit components and were non-damaging, and 3) the suit and related components are qualified for the Orion random vibration environments.

Jeffrey D Suhey↗

NASA NTRSDate not supplied

Overview of Integrated Random Vibration Testing of the NASA Orion Crew Survival Suit

The launch ascent and abort random vibration environments from NASA’s Orion spacecraft drove the need to test the NASA Orion Crew Survival Suit as an integrated system with exposure to the design levels. In order to properly characterize component responses, a series of integrated tests were designed to incorporate the interaction between a crew member, suit, seat, and the attenuation system. The first Development Test (2017) included human subjects, and was performed with early development seat and suit components, and low level inputs. It provided a baseline for frequency response and behavior of the integrated system. The next two tests, Development Test (2019) and Qualification Test (2020), used manikin surrogates to represent the crew member and increasing levels of component hardware fidelity in order to test to higher input levels. Testing was performed at NASA Johnson Space Center (JSC) and Kennedy Space Center (KSC) Vibration Labs and provided the input levels required to represent the ascent and abort vehicle profiles as well as recorded component response behavior from accelerometer instrumentation and high speed cameras. Inspection of the suit and related components showed that for all seat orientations, and input environments, no damage occurred. Additional pre and post-test checks confirmed the functionality of all suited hardware. Response data of the suited components generally showed heavy attenuation across most of the tested frequency range. Transmissibility plots showed some amplification of components at lower frequency ranges. Overall this series of integrated tests showed that 1) the use of surrogate manikins in the tests were adequate for representing crew in a vibration environment, 2) full vibration levels for ascent and abort were heavily attenuated in the suit components and were non-damaging, and 3) the suit and related components are qualified for the Orion random vibration environments.

Jeffrey Suhey↗

NASA NTRS2018

Comparing Free-Free and Shaker Table Model Correlation Methods Using Jim Beam

Finite element model correlation as part of a spacecraft program has always been a challenge. For any NASA mission, the coupled system response of the spacecraft and launch vehicle can be determined analytically through a Coupled Loads Analysis (CLA), as it is not possible to test the spacecraft and launch vehicle coupled system before launch. The value of the CLA is highly dependent on the accuracy of the frequencies and mode shapes extracted from the spacecraft model. NASA standards require the spacecraft model used in the final Verification Loads Cycle to be correlated by either a modal test or by comparison of the model with Frequency Response Functions (FRFs) obtained during the environmental qualification test. Due to budgetary and time constraints, most programs opt to correlate the spacecraft dynamic model during the environmental qualification test, conducted on a large shaker table. For any model correlation effort, the key has always been finding a proper definition of the boundary conditions. This paper is a correlation case study to investigate the difference in responses of a simple structure using a free-free boundary, a fixed boundary on the shaker table, and a base-drive vibration test, all using identical instrumentation. The NAVCON Jim Beam test structure, featured in the IMAC round robin modal test of 2009, was selected as a simple, well recognized and well characterized structure to conduct this investigation. First, a free-free impact modal test of the Jim Beam was done as an experimental control. Second, the Jim Beam was mounted to a large 20,000 lbf shaker, and an impact modal test in this fixed configuration was conducted. Lastly, a vibration test of the Jim Beam was conducted on the shaker table. The free-free impact test, the fixed impact test, and the base-drive test were used to assess the effect of the shaker modes, evaluate the validity of fixed-base modeling assumptions, and compare final model correlation results between these boundary conditions.

Modal Test↗

NASA NTRS2004

COTS Ceramic Chip Capacitors: An Evaluation of the Parts and Assurance Methodologies

Commercial-Off-The-Shelf (COTS) multilayer ceramic chip capacitors (MLCCs) are continually evolving to reduce physical size and increase volumetric efficiency. Designers of high reliability aerospace and military systems are attracted to these attributes of COTS MLCCs and would like to take advantage of them while maintaining the high standards for long-term reliable operation they are accustomed io when selecting military qualified established reliability (MIL-ER) MLCCs. However, MIL-ER MLCCs are not available in the full range of small chip sizes with high capacitance as found in today's COTS MLCCs. The objectives for this evaluation were to assess the long-term performance of small case size COTS MLCCs and to identify effective, lower-cost product assurance methodologies. Fifteen (15) lots of COTS X7R dielectric MLCCs from four (4) different manufacturers and two (2) MIL-ER BX dielectric MLCCs from two (2) of the same manufacturers were evaluated. Both 0805 and 0402 chip sizes were included. Several voltage ratings were tested ranging from a high of 50 volts to a low of 6.3 volts. The evaluation consisted of a comprehensive screening and qualification test program based upon MIL-PRF-55681 (i.e., voltage conditioning, thermal shock, moisture resistance, 2000-hour life test, etc.). In addition, several lot characterization tests were performed including Destructive Physical Analysis (DPA), Highly Accelerated Life Test (HALT) and Dielectric Voltage Breakdown Strength. The data analysis included a comparison of the 2000-hour life test results (used as a metric for long-term performance) relative to the screening and characterization test results. Results of this analysis indicate that the long-term life performance of COTS MLCCs is variable -- some lots perform well, some lots perform poorly. DPA and HALT were found to be promising lot characterization tests to identify substandard COTS MLCC lots prior to conducting more expensive screening and qualification tests. The results indicate that lot- specific screening and qualification are still recommended for high reliability applications. One significant and concerning observation is that MIL- type voltage conditioning (100 hours at twice rated voltage, 125 C) was not an effective screen in removing infant mortality parts for the particular lots of COTS MLCCs evaluated.

Brusse, Jay A.↗

NASA NTRS1999

Position Estimation Verification Testing for the Video Guidance Sensor and Dynamic Overhead Target Simulator

The Video Guidance Sensor, part of the Automated Rendezvous and Capture mechanism, is due to undergo formal qualification testing at Marshall Space Flight Center. Before it undergoes this qualification, a test was needed to verify repeatability of the sensor, and to allow different sensor configurations to be compared. This test was developed at the Flight Robotics Laboratory. The test uses a software script to drive the sensor target to the same position and thus allows sensor runs to be compared. The sensor target is the Dynamic Overhead Target Simulator. The simulator uses encoders as its position indicator. Distance Measuring Device's were used to independently verify the software script, the sensor reading, and the target position. The test area, sensor, and other test equipment are briefly described. The actual data is tabulated and will serve as a baseline for future tests. The software script was found to be adequate for the test. Position repeatability was acceptable for all the equipment. The system test is now ready to be used in formal qualification testing.

Gaines, Joseph↗