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At least 163 records · Page 9

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NASA NTRS1995

Flexible Borescope For Inspecting Ducts

Borescope and associated equipment developed specifically for use in optical inspection of inside of flexible joints in rocket-engine fuel duct. Apparatus includes assembly, characterized as "mouse/canoe," at sensing end of 10-ft borescope cable. Borescope tip rides in mouse/canoe. The mouse/canoe made laterally compressible, to facilitate movement past constrictions and provides fixed distance from inspection point permitting accurate description in duct inspected.

Shinozaki, Keith↗

NASA NTRS1996

Laser-Scan Ultrasonic/Thermographic Inspection System

Laser ultrasonic/thermographic inspection system is conceptual instrument used in nondestructive inspection of large areas of structures for subsurface defects. For example, operated in field to examine aircraft and pressure vessels for hidden cracks. System would not require contact with inspected structure or use of ultrasonic-coupling medium. Instrument obtains data in ultrasonic and thermographic C-scans over structural surfaces with contours characterized by surface normal vectors varying by angles as large as 45 degrees.

Bar-Cohen, Yoseph↗

NASA NTRS1995

Follow-the-leader algorithm for the payload inspection and processing system

This report summarizes the author's summer 1995 work at NASA Kennedy Space Center in the Advanced System Division. The assignment was path planning for the Payload Inspection and Processing System (PIPS). PIPS is an automated system, programmed off-line for inspection of Space Shuttle payloads after integration and prior to launch. PIPS features a hyper-redundant 18-dof serpentine truss manipulator capable of snake-like motions to avoid obstacles. The path planning problem was divided into two segments: (1) determining an obstacle-free trajectory for the inspection camera at the manipulator tip to follow; and (2) development of a follow-the-leader (FTL) algorithm which ensures whole-arm collision avoidance by forcing ensuing links to follow the same tip trajectory. The summer 1995 work focused on the FTL algorithm. This report summarizes development, implementation, testing, and graphical demonstration of the FTL algorithm for prototype PIPS hardware. The method and code was developed in a modular manner so the final PIPS hardware may use them with minimal changes. The FTL algorithm was implemented using MATLAB software and demonstrated with a high-fidelity IGRIP model. The author also supported implementation of the algorithm in C++ for hardware control. The FTL algorithm proved to be successful and robust in graphical simulation. The author intends to return to the project in summer 1996 to implement path planning for PIPS.

Williams, Robert L., II↗

NASA NTRS2001

Advances in the Use of Thermography to Inspect Composite Tanks for Liquid Fuel Propulsion Systems

This viewgraph presentation gives an overview of advances in the use of thermography to inspect composite tanks for liquid fuel propulsion systems. Details are given on the thermographic inspection system, thermographic analysis method (includes scan and defect map, method of inspection, and inclusions, ply wrinkle, and delamination defects), graphite composite cryogenic feedline (including method, image map, and deep/shallow inclusions and resin rich area defects), and material degradation nondestructive evaluation.

Lansing, Matthew D.↗

NASA NTRS2004

Hubble Space Telescope Fine Guidance Sensor Post-Flight Bearing Inspection

Aerospace mechanism engineering success stories often, if not always, consist of overcoming developmental, test and flight anomalies. Many times it is these anomalies that stimulate technology growth and more reliable future systems. However, one must learn from these to achieve an ultimately successful mission. It is not often that a spacecraft engineer is able to inspect hardware that has flown in orbit for several years. However, in February 1997, the Fine Guidance Sensor-I (FGS-1) was removed from the Hubble Space Telescope (HST) and returned to NASA Goddard Space Flight Center (GSFC) during the second Servicing Mission (SM2). At the time of removal, FGS-1 had nearly 7 years of service and the bearings in the Star Selector Servos (SSS) had accumulated approximately 25 million Coarse Track (CT) cycles. The main reason for its replacement was due to a bearing torque anomaly leading to stalling of the B Star Selector Servo (SSS-B) when reversing direction during a vehicle offset maneuver, referred to herein as a Reversal Bump (RB). The returned HST FGS SSS bearings were disassembled for post-service condition assessment to better understand the actual cause of the torque spikes, identify potential process/design improvements, and provide information for remedial on-orbit operation modifications. The methods and technology utilized for this inspection are not unique to this system and can be adapted to most investigation ai varying stages of the mechanism life from development, through testing, io post night evaluation. The systematic methods used for the HST Fine Guidance Sensor (FGS) SSS and specific findings are the subjects presented in this paper. The lessons learned include the importance of cleanliness and handling for precision instrument bearings and the potential effects from contamination. The paper describes in detail, the analytical techniques used for the SSS and their importance in this investigation. Inspection analytical data and photographs are included throughout the paper.

Pellicciotti, Joseph↗

NASA NTRS2004

Hubble Space Telescope Fine Guidance Sensor Post-Flight Bearing Inspection

Aerospace mechanism engineering success stories often, if not always, consist of overcoming developmental, test and flight anomalies. Many times it is these anomalies that stimulate technology growth and more reliable future systems. However, one must learn from these to achieve an ultimately successful mission. It is not often that a spacecraft engineer is able to inspect hardware that has flown in orbit for several years. However, in February 1997, the Fine Guidance Sensor-1 (FGS-1) was removed from the Hubble Space Telescope (HST) and returned to NASA Goddard Space Flight Center (GSFC) during the second Servicing Mission (SM2). At the time of removal, FGS-1 had nearly 7 years of service and the bearings in the Star Selector Servos (SSS) had accumulated approximately 25 million Coarse Track (CT) cycles. The main reason for its replacement was due to a bearing torque anomaly leading to stalling of the B Star Selector Servo (SSS-B) when reversing direction during a vehicle offset maneuver, referred to herein as a Reversal Bump (RB). The returned HST FGS SSS bearings were disassembled for post-service condition assessment to better understand the actual cause of the torque spikes, identify potential process/design improvements, and provide information for remedial on-orbit operation modifications. The methods and technology utilized for this inspection are not unique to this system and can be adapted to most investigations at varying stages of the mechanism life from development, through testing, to post flight evaluation. The systematic methods used for the HST Fine Guidance Sensor (FGS) SSS and specific findings are the subjects presented in this paper. The lessons learned include the importance of cleanliness and handling for precision instrument bearings and the potential effects from contamination. The paper describes in detail, the analytical techniques used for the SSS and their importance in this investigation. Inspection analytical data and photographs are included throughout the paper.

Pellicciotti, J.↗

NASA NTRS1990

Mueller-Lyer decrement: practice or prolonged inspection?

Noting the similarity between the illusion decrement and selective adaptation paradigms, Long has challenged the view that illusion decrement effects reflect a strategic--as opposed to a structural--underlying mechanism, and has called for further research on this issue. To investigate the confound between prolonged free inspection and repeated trials in the standard decrement procedure, the effects of three inspection conditions (continuous, intermittent, and immediate) on the magnitude of the overestimation Mueller-Lyer illusion have been assessed under two levels of trials (a total of two or six judgments). Significant illusion decline was found only under conditions of repeated trials, with either continuous or intermittent inspection. These findings do not support the predictions of purely structural theories (including neural adaptation and efferent readiness theories), according to which degree of decrement should be determined solely by viewing time. Instead, the data demonstrate that illusion decrement is a product of practice, providing converging evidence for the view of decrement as involving a cognitive 'recalibration' or learning process.

Form Perception↗

NASA NTRS2005

Inspection of the Space Shuttle External Tank SOFI Using Near-Field and Focused Millimeter Wave Nondestructive Testing Techniques

The Space Shuttle Columbia's catastrophic failure has been attributed to a piece of external tank SOFI (Spray On Foam Insulation) striking the left wing of the orbiter causing significant damage to some of the reinforced carbon/carbon leading edge wing panels. Subsequently, several nondestructive testing (NDT) techniques have been considered for inspecting the external tank. One such method involves using millimeter waves which have been shown to easily penetrate through the foam and provide high resolution images of its interior structures. This paper presents the results of inspecting three different SOFI covered panels by reflectometers at millimeter wave frequencies, specifically at 100 GHz. Each panel was fitted with various embedded anomalies/inserts representing voids and unbonds of diferent shapes, sizes and locations within each panel. In conjunction with these reJqectome&rs, radiators including a focused lens antenna and a small horn antenna were used. The focused lens antenna provided for a footprint diameter of approximately 1.25 cm (0.5") at 25.4 cm (10") away from the lens surface. The horn antenna was primarily operated in its near-field for obtaining relatively high resolution images. These images were produced using 2 0 scanning mechanisms. Discussions of the difference between the capabilities of these two types of antennas (radiators) for the purpose of inspecting the SOFI as it relates to the produced images are also presented.

Kharkovsky, S.↗

NASA NTRS2002

Scanning Ultrasonic Spectroscopy System Developed for the Inspection of Composite Flywheels

Composite flywheels are being considered as replacements for chemical batteries aboard the International Space Station. A flywheel stores energy in a spinning mass that can turn a generator to meet power demands. Because of the high rotational speeds of the spinning mass, extensive testing of the flywheel system must be performed prior to flight certification. With this goal in mind, a new scanning system has been developed at the NASA Glenn Research Center for the nondestructive inspection of composite flywheels and flywheel subcomponents. The system uses ultrasonic waves to excite a material and examines the response to detect and locate flaws and material variations. The ultrasonic spectroscopy system uses a transducer to send swept-frequency ultrasonic waves into a test material and then receives the returning signal with a second transducer. The received signal is then analyzed in the frequency domain using a fast Fourier transform. A second fast Fourier transform is performed to examine the spacing of the peaks in the frequency domain. The spacing of the peaks is related to the standing wave resonances that are present in the material because of the constructive and destructive interferences of the waves in the full material thickness as well as in individual layers within the material. Material variations and flaws are then identified by changes in the amplitudes and positions of the peaks in both the frequency and resonance spacing domains. This work, conducted under a grant through the Cleveland State University, extends the capabilities of an existing point-by-point ultrasonic spectroscopy system, thus allowing full-field automated inspection. Results of an ultrasonic spectroscopy scan of a plastic cylinder with intentionally seeded flaws. The result of an ultrasonic spectroscopy scan of a plastic cylinder used as a proof-of-concept specimen is shown. The cylinder contains a number of flat bottomed holes of various sizes and shapes. The scanning system was able to successfully detect all the defects in the material. Ultrasonic spectroscopy results for a second specimen are shown along with a conventional ultrasonic C-scan. The second specimen is a section of a flywheel subcomponent that has a series of drilled holes and notches. This specimen is employed as a defect detection standard to evaluate the various nondestructive evaluation methods under consideration. Scanning results demonstrate the ability of the system to detect flaws on the order of 10 mils in the radial direction and 5 mils in the circumferential direction. Work conducted to date has shown that scanning ultrasonic spectroscopy is a viable tool for the inspection of composite flywheel systems. Ongoing development work is focused on refining the system and scanning parameters for improved resolution and defect detection.

Martin, Richard E.↗

NASA NTRS2006

Inspection and Verification of Domain Models with PlanWorks and Aver

When developing a domain model, it seems natural to bring the traditional informal tools of inspection and verification, debuggers and automated test suites, to bear upon the problems that will inevitably arise. Debuggers that allow inspection of registers and memory and stepwise execution have been a staple of software development of all sorts from the very beginning. Automated testing has repeatedly proven its considerable worth, to the extent that an entire design philosophy (Test Driven Development) has been developed around the writing of tests. Unfortunately, while not entirely without their uses, the limitations of these tools and the nature of the complexity of models and the underlying planning systems make the diagnosis of certain classes of problems and the verification of their solutions difficult or impossible. Debuggers provide a good local view of executing code, allowing a fine-grained look at algorithms and data. This view is, however, usually only at the level of the current scope in the implementation language, and the data-inspection capabilities of most debuggers usually consist of on-line print statements. More modem graphical debuggers offer a sort of tree view of data structures, but even this is too low-level and is often inappropriate for the kinds of structures created by planning systems. For instance, god or constraint networks are at best awkward when visualized as trees. Any any non-structural link between data structures, as through a lookup table, isn't captured at all. Further, while debuggers have powerful breakpointing facilities that are suitable for finding specific algorithmic errors, they have little use in the diagnosis of modeling errors.

Bedrax-Weiss, Tania↗

NASA NTRS2004

Mini AERCam Inspection Robot for Human Space Missions

The Engineering Directorate of NASA Johnson Space Center has developed a nanosatellite-class free-flyer intended for future external inspection and remote viewing of human spacecraft. The Miniature Autonomous Extravehicular Robotic Camera (Mini AERCam) technology demonstration unit has been integrated into the approximate form and function of a flight system. The spherical Mini AERCam free flyer is 7.5 inches in diameter and weighs approximately 10 pounds, yet it incorporates significant additional capabilities compared to the 35 pound, 14 inch AERCam Sprint that flew as a Shuttle flight experiment in 1997. Mini AERCam hosts a full suite of miniaturized avionics, instrumentation, communications, navigation, imaging, power, and propulsion subsystems, including digital video cameras and a high resolution still image camera. The vehicle is designed for either remotely piloted operations or supervised autonomous operations including automatic stationkeeping and point-to-point maneuvering. Mini AERCam is designed to fulfill the unique requirements and constraints associated with using a free flyer to perform external inspections and remote viewing of human spacecraft operations. This paper describes the application of Mini AERCam for stand-alone spacecraft inspection, as well as for roles on teams of humans and robots conducting future space exploration missions.

Fredrickson, Steven E.↗

NASA NTRS1997

Autonomous Rapid Inspection of Aerospace Structures

Effective assurance of the integrity and performance of aging aircraft sturnctures, particularly those that are made of composite materials, requires rapid inspection of large area. Removal from the aircraft for NDE at an inspection facility is no economical and preferable the inspection should be performed at the field setting.

Aerospace Structure↗

NASA NTRS2006

AERCam Autonomy: Intelligent Software Architecture for Robotic Free Flying Nanosatellite Inspection Vehicles

The NASA Johnson Space Center has developed a nanosatellite-class Free Flyer intended for future external inspection and remote viewing of human spacecraft. The Miniature Autonomous Extravehicular Robotic Camera (Mini AERCam) technology demonstration unit has been integrated into the approximate form and function of a flight system. The spherical Mini AERCam Free Flyer is 7.5 inches in diameter and weighs approximately 10 pounds, yet it incorporates significant additional capabilities compared to the 35-pound, 14-inch diameter AERCam Sprint that flew as a Shuttle flight experiment in 1997. Mini AERCam hosts a full suite of miniaturized avionics, instrumentation, communications, navigation, power, propulsion, and imaging subsystems, including digital video cameras and a high resolution still image camera. The vehicle is designed for either remotely piloted operations or supervised autonomous operations, including automatic stationkeeping, point-to-point maneuvering, and waypoint tracking. The Mini AERCam Free Flyer is accompanied by a sophisticated control station for command and control, as well as a docking system for automated deployment, docking, and recharge at a parent spacecraft. Free Flyer functional testing has been conducted successfully on both an airbearing table and in a six-degree-of-freedom closed-loop orbital simulation with avionics hardware in the loop. Mini AERCam aims to provide beneficial on-orbit views that cannot be obtained from fixed cameras, cameras on robotic manipulators, or cameras carried by crewmembers during extravehicular activities (EVA s). On Shuttle or International Space Station (ISS), for example, Mini AERCam could support external robotic operations by supplying orthogonal views to the intravehicular activity (IVA) robotic operator, supply views of EVA operations to IVA and/or ground crews monitoring the EVA, and carry out independent visual inspections of areas of interest around the spacecraft. To enable these future benefits with minimal impact on IVA operators and ground controllers, the Mini AERCam system architecture incorporates intelligent systems attributes that support various autonomous capabilities. 1) A robust command sequencer enables task-level command scripting. Command scripting is employed for operations such as automatic inspection scans over a region of interest, and operator-hands-off automated docking. 2) A system manager built on the same expert-system software as the command sequencer provides detection and smart-response capability for potential system-level anomalies, like loss of communications between the Free Flyer and control station. 3) An AERCam dynamics manager provides nominal and off-nominal management of guidance, navigation, and control (GN&C) functions. It is employed for safe trajectory monitoring, contingency maneuvering, and related roles. This paper will describe these architectural components of Mini AERCam autonomy, as well as the interaction of these elements with a human operator during supervised autonomous control.

Fredrickson, Steven E.↗

NASA NTRS2007

NDE Development for Inspection of the Ares I Crew Launch Vehicle

NASA is designing a new crewed launch vehicle called Ares I to replace the Space Shuttle after its scheduled retirement in 2010. This new launch vehicle will build on the Shuttle technology in many ways including using a first stage based upon the Space Shuttle Solid Rocket Booster, advanced aluminum alloys for the second stage tanks, and friction stir welding to assemble the second stage. Friction stir welding uses a spinning pin that is inserted in the joint between two panels that are to be welded. The pin mechanically mixes the metal together below the melting temperature to form the weld. Friction stir welding allows high strength joints in metals that would otherwise lose much of their strength as they are melted during the fusion welding process. One significant change from the Space Shuttle that impacts NDE is the implementation of self-reacting friction stir welding for non-linear welds on the primary metallic structure. The self-reacting technique differs from the conventional technique because the load of the pin tool pressing down on the metal being joined is reacted by a nut on the end of the tool rather than an anvil behind the part. No spacecraft has ever flown with a self-reacting friction stir weld, so this is a major advancement in the manufacturing process, bringing with it a whole new set of challenges for NDE to overcome. Another impact is the proposed usage of an aluminum face sheet, phenolic honeycomb sandwich structure for a common bulkhead between the fuel and oxidizer tanks. This design was used on the second stage of Saturn IB and the second and third stages of Saturn V, but both the manufacturing and subsequent inspection were very costly and time consuming so a more efficient inspection method is sought. The current state of development of these inspections will be presented, along with other information pertinent to NDE of the Ares I.

Richter, Joel↗

NASA NTRS2007

Validation Test Results for Orthogonal Probe Eddy Current Thruster Inspection System

Recent nondestructive evaluation efforts within NASA have focused on an inspection system for the detection of intergranular cracking originating in the relief radius of Primary Reaction Control System (PCRS) Thrusters. Of particular concern is deep cracking in this area which could lead to combustion leakage in the event of through wall cracking from the relief radius into an acoustic cavity of the combustion chamber. In order to reliably detect such defects while ensuring minimal false positives during inspection, the Orthogonal Probe Eddy Current (OPEC) system has been developed and an extensive validation study performed. This report describes the validation procedure, sample set, and inspection results as well as comparing validation flaws with the response from naturally occuring damage.

Wincheski, Russell A.↗

NASA NTRS2008

Probability of Detection Study on Impact Damage to Honeycomb Composite Structure using Thermographic Inspection

A probability of detection study was performed for the detection of impact damage using flash heating infrared thermography on a full scale honeycomb composite structure. The honeycomb structure was an intertank structure from a previous NASA technology demonstration program. The intertank was fabricated from IM7/8552 carbon fiber/epoxy facesheets and aluminum honeycomb core. The intertank was impacted in multiple locations with a range of impact energies utilizing a spherical indenter. In a single blind study, the intertank was inspected with thermography before and after impact damage was incurred. Following thermographic inspection several impact sites were sectioned from the intertank and cross-sectioned for microscopic comparisons of NDE detection and actual damage incurred. The study concluded that thermographic inspection was a good method of detecting delamination damage incurred by impact. The 90/95 confidence level on the probability of detection was close to the impact energy that delaminations were first observed through cross-sectional analysis.

Hodge, Andrew J.↗

NASA NTRS2009

Recent Shuttle Post Flight MMOD Inspection Highlights

Post flight inspections on the Space Shuttle Atlantis conducted after the STS-11.5 mission revealed a 0.11 inch (2.8 mm) hole in the outer face sheet of the starboard payload bay door radiator panel #4. The payload bay door radiators in this region are 0.5 inch (12.7 mm) thick aluminum honeycomb with 0.011 in (0.279 mm) thick aluminum face sheets topped with 0.005 in (0.127 mm) silver-Teflon tape. Inner face sheet damage included a 0.267 in (6.78 mm) long through crack with measureable deformation in the area of 0.2 in (5.1 mm). There was also a 0.031 in (0.787 nun) diameter hole in the rear face sheet. A large approximately l in (25 mm) diameter region of honeycomb was also destroyed. Since the radiators are located on the inside of the shuttle payload bay doors which are closed during ascent and reentry, the damage could only have occurred during the on-orbit portion of the mission. During the August 2007 STS-118 mission to the International Space Station, a micro-meteoroid or orbital debris (MMOD) particle impacted and completely penetrated one of shuttle Endeavour's radiator panels and the underlying thermal control system (TCS) blanket, leaving deposits on (but no damage to) the payload bay door. While it is not unusual for shuttle orbiters to be impacted by small MMOD particles, the damage from this impact is larger than any previously seen on the shuttle radiator panels. One of the largest impacts ever observed on a crew module window occurred during the November 2008 STS-126 mission to the International Space Station. Damage to the window was documented by the crew on orbit. Post flight inspection revealed a 0.4 in (10.8 mm) crater in the window pane, with a depth of 0.03 in (0.76 mm). The window pane was replaced due to the damage caused by this impact. Analysis performed on residue contained in dental mold impressions taken of the site indicated that a meteoroid particle produced this large damage site. The post flight inspection after the subsequent mission, STS-119 in March of 2009, produced a large MMOD impact feature in a wing leading edge reinforced carbon-carbon panel. The crater measured 0.18 in (4.5 nun) in diameter and was nearly 0.037 in (0.93 nun) deep. The thickness of the silicon carbide coating that protects the carbon substrate is nominally 0.02 in (0.5 nun) to 0.04 in (1 mm), making this a significant impact into the RCC. The damage occurred on the upper surface of the panel, which experiences lower heat loads on re-entry. This poster will document the data collected from the impact sites and will include results of the Scanning Electron Microscope/Energy Dispersive X-ray (SEM/EDX) analysis. Evidence will be presented that suggests a source of the impacts.

Hyed, James L.↗

NASA NTRS2010

Develop Critical Profilometers to Meet Current and Future Composite Overwrapped Pressure Vessel (COPV) Interior Inspection Needs

The objective of this project is to develop laser profilometer technology that can efficiently inspect and map the inside of composite pressure vessels for flaws such as liner buckling, pitting, or other surface imperfections. The project will also provide profilometers that can directly support inspections of flight vessels during development and qualification programs and subsequently be implemented into manufacturing inspections to screen out vessels with "out of family" liner defects. An example interior scan of a carbon overwrapped bottle is shown in comparison to an external view of the same bottle (Fig. 1). The internal scan is primarily of the cylindrical portion, but extends about 0.15 in. into the end cap area.

Saulsberry, Regor L.↗