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NASA NTRSDate not supplied

Application of Norton-Thevenin Receptance Coupling (NTRC) to Space Launch System (SLS) Payload Coupled Loads Analysis (CLA)

Norton-Thevenin Receptance Coupling (NTRC), as described in several NASA Engineering and Safety Center (NESC) papers shows promise in enabling loads development for payloads with less computational cost and analyst time as compared to a full integrated vehicle coupled loads analysis (CLA). NTRC allows the free vehicle responses and impedance (accelerance) at the payload to vehicle interface (derived from integrated vehicle CLA) to be used with a payload model in a payload CLA. Due to the NTRC damping differing from the full integrated vehicle damping, results are slightly different, so coverage factors were developed to ensure NTRC results enveloped results from a traditional CLA. NTRC results with coverage factors were very close to full CLA results. The Space Launch System (SLS) coupled loads team has developed an implementation of the NTRC method to enable support of co-manifested payloads with analysis needs that do not fit the primary SLS load cycle schedule. The NTRC method was successfully used to support the European System Providing Refueling, Infrastructure, and Communications (ESPRIT) module for Gateway planned to fly on Artemis V and has been adopted as the SLS approach for supporting payload CLA requests that do not align with vehicle load cycles.

SLS↗

NASA NTRS2018

Historical Perspective on Fast Coupled Loads Analysis Methods

Spacecraft structural designs are typically verified through a coupled loads analysis (CLA) process, which couples the spacecraft model with the launch vehicle (LV) model to predict low-frequency quasi-static and dynamic responses. The CLA calculations are typically the responsibility of the LV organization, but the spacecraft organization has a vested interest in being able to calculate approximate CLA results during the design of the spacecraft. Because of this, there has long been interest in a method that would allow a spacecraft organization to perform a CLA without access to the full set of LV models and forcing functions. One such method is the Norton-Thevenin Receptance Coupling (NTRC) approach, which is specifically designed to accurately transform LV free accelerations (no payload) into coupled system accelerations (LV plus payload). The purpose of this report is to provide historical context for the NTRC method and compare it with methods that have been used in the past. In particular, it is compared to a frequency-domain substitution method that had been used for a long period of time at the Jet Propulsion Laboratory, and a component-mode-based equivalent to that method.

Blelloch, Paul A.↗

NASA NTRS2023

Fast Coupled Loads Analysis Method: Norton-Thevenin Receptance Coupling

A new method called Norton-Thevenin Receptance Coupling (NTRC) has been developed to perform coupled loads analysis (CLA). NTRC provides a tool that payload developers can use to obtain launch loads at a fraction of the cost of a CLA any time it is required in the payload design cycle. NTRC combines the frequency domain component coupling method of Receptance Coupling with the Norton and Thevenin theory used in force limiting to derive an alternate method for performing CLA.

Coupled Loads Analysis↗

NASA NTRSDate not supplied

Variational Coupled Loads Analysis using the Hybrid Parametric Variation Method

Time-domain coupled loads analysis (CLA)is used to determine the response of a launch vehicle and payload system to transient forces, such as liftoff, engine ignitions and shutdowns, jettison events, and atmospheric flight loads, such as buffet. CLA, using Hurty/Craig-Bampton (HCB)component models, is the accepted method for the establishment of design-level loads for launch systems. However, uncertainty in the component models flows into uncertainty in predicted system results. Uncertainty in the structural responses during launch is a significant concern because small variations in launch vehicle and payload mode shapes and their interactions can result in significant variations in system loads. Uncertainty quantification (UQ)is used to determine statistical bounds on prediction accuracy based on model uncertainty. In this paper uncertainty is treated at the HCB component-model level. In an effort to account for model uncertainties and statistically bound their effect on CLA predictions, this work combines CLA with UQ in a process termed variational coupled loads analysis (VCLA). The modeling of uncertainty using a parametric approach, in which input parameters are represented by random variables, is common, but its major drawback is the resulting uncertainty is limited to the form of the nominal model. Uncertainty in model form is one of the biggest contributors to uncertainty in complex built-up structures. Model-form uncertainty can be represented using a nonparametric approach based on random matrix theory (RMT). In this work, UQ is performed using the hybrid parametric variation (HPV)method, which combines parametric with nonparametric uncertainty at the HCB component model level. The HPV method requires the selection of dispersion values for the HCB fixed-interface (FI)eigenvalues, and the HCB mass and stiffness matrices. The dispersions are based upon component test-analysis modal correlation results. During VCLA, random component models are assembled into an ensemble of random systems using a Monte Carlo (MC)approach. CLA is applied to each of the ensemble members to produce an ensemble of system-level responses for statistical analysis. The proposed methodology is demonstrated through its application to a buffet loads analysis of NASA’s Space Launch System (SLS)during the transonic regime fifty seconds after liftoff. Core stage (CS)section shears and moments are recovered, and statistics are computed.

Uncertainty Quantification↗

NASA NTRS2018

An Examination of Launch Vehicle Loads Reanalysis Techniques

The typical approach to calculating dynamic launch loads in aerospace applications is coupled loads analysis (CLA). A component mode model of the launch vehicle is coupled with a component mode model of a payload, system modes are calculated, forcing functions are applied, and the dynamic responses are computed. This approach requires the explicit knowledge of the component models for the launch vehicle and payload, as well as the forcing functions. In many situations, the launch vehicle and forcing functions do not change from one analysis to the next only the payload is different. For this type of application, a method called reanalysis was developed to compute the response of a modified payload on the same launch vehicle. If the launch forcing functions are also the same, the approach eliminates the need for the launch vehicle model and the forcing functions and dramatically reduces the computation time. This work investigates the application and accuracy of three previously developed reanalysis methods using a typical launch vehicle and two different payloads. All three methods are based on knowledge of system modes from the original CLA, and Hurty/Craig-Bampton (HCB) models of the original and new payloads. The first method was developed at JPL (Jet Propulsion Lab) and is often referred to as substitution. It is a frequency-domain method, which requires transformation of time signals to and from the frequency domain. The other two methods are time-domain methods that more closely mimic the CLA process. The three methods were applied to two simple examples and a more complex one. The results indicate that the time-domain methods are considerably more robust with respect to modal truncation and other numerical errors than the frequency-domain JPL method.

Reanalysis↗

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 NTRSDate not supplied

SLS Payload Launch Loads Analysis Using the NTRC Method

SLS↗

NASA NTRSDate not supplied

A Flexible Multibody Approach to Space Launch System Liftoff Pad Separation with Umbilical Disconnect

A flexible multibody dynamic framework is applied to the Space Launch System (SLS) liftoff Coupled Loads Analysis (CLA), enabling computational efficiencies and systematic inclusion of components and various nonlinearities. The objective of this work is to simulate the SLS liftoff transient pad separation event inclusive of umbilical disconnects. The vehicle stacking preloads and cryogenically induced preloads, due to the fueling of the Core Stage (CS), are integrated via specialized deformed coupling procedure to ensure full capture of the liftoff transient event. The Vehicle Stabilizer System (VSS) hydraulic struts are nonlinear and provide amplitude dependent damping, significantly contributing to the liftoff transient event. Ground Extensible Columns (EC) provide additional stiffness and preloads on the Mobile Launcher (ML), also significantly contributing to the liftoff transient. An advanced Henkel-Mar algorithm, with separation and re-contact, thus tracking the potential post separation re-contact between the booster aft skirt and ML, the umbilicals and vehicle, and ground EC separation. For this system level nonlinear dynamic simulation, the flexible multibody framework provides a systematic approach for the addition of component specific algorithms to enforce nonlinearities. This multibody framework is similar to an object-oriented programming language integrating classes of associated subroutines. As such, the complexities associated with the nonlinear CLA are greatly reduced, facilitating simplified bookkeeping as well as accelerating the execution of the nonlinear time-domain simulations.

Joel W Sills Jr.↗

NASA NTRSDate not supplied

An Application of Flexible Multibody Simulations to Space Launch Systems Liftoff Pad Separation and Umbilical Disconnect

A flexible multibody dynamics approach is applied to the Space Launch System (SLS) liftoff Coupled Loads Analysis (CLA), enabling the inclusion of a large array of component nonlinearities with extreme computational efficiency. The nonlinearities include the cryogenic induced preloads due to the large rotations of the aft struts connecting the Core Stage (CS) to the boosters, the contact/separation and potential re-contact at the booster aft skirt to Mobile Launcher(ML) interface, contact/separation and potential re-contact at the ML/extensible columns interfaces, secondary disconnect of the CS umbilicals including the LOX and LH2 Tail Service Mast Umbilicals (TSMUs), and the disconnect of the upper stage umbilical, the Interim Cryogenic Propulsion Stage Umbilical (ICPSU). The ICPSU disconnect involves algorithms simulating the winch motors reeling lanyard ropes, the nonlinear modeling of ropes and hoses, the disconnect and capture of multiple umbilical ground plates by catch-nets (geometrically nonlinear models), and the large rotations of the ML gantry in order to track clearances between the lifting SLS vehicle and umbilicals rotating out of the way. The flexible multibody dynamics framework utilized for these simulations provided a systematic and efficient framework for adding complex nonlinearities at the system level which would have otherwise not been possible in standard CLAs or would have to be treated by separate local analyses thereby not accounting for the coupled system behavior.

Application↗

NASA NTRS2011

Lessons Learned from Shuttle Payload Verification Loads Analysis

When a system experiences a loading environment characterized by rapidly varying forces, such as a rocket launch, a transient analysis is used to analyze the response of the system. The most common transient analysis methodology is the Coupled Loads Analysis (CLA). CLAs are used by the automotive and aerospace industry to analyze cars, trucks, planes, helicopters, spacecraft, etc. The Space Shuttle program also uses the CLA methodology to assess the compatibility of the payload with the Orbiter and the flight environment. The Space Shuttle Verification Loads Analysis (VLA) was a standardized process that started between ten and thirteen months prior to launch, and included several meetings as well as analysis by both the Shuttle Program and the payload developers. Over the course of the Space Shuttle Program, many improvements were made to the process which helped to reduce cycle time and improve manifest flexibility. There were also several issues which were never properly addressed, but a work-around would be developed to keep the process flowing. The lessons learned included automation of some processes and standardization of others, early assessments, improved documentation and better coordination with all stakeholders in the process. Lessons learned also included the limitations in the current process, and what needs to be planned for in the future to avoid the same issues.

Bruno, Erica↗

NASA NTRS2015

Coupled Loads Analysis of the Modified NASA Barge Pegasus and Space Launch System Hardware

A Coupled Loads Analysis (CLA) has been performed for barge transport of Space Launch System hardware on the recently modified NASA barge Pegasus. The barge re-design was facilitated with detailed finite element analyses by the ARMY Corps of Engineers - Marine Design Center. The Finite Element Model (FEM) utilized in the design was also used in the subject CLA. The Pegasus FEM and CLA results are presented as well as a comparison of the analysis process to that of a payload being transported to space via the Space Shuttle. Discussion of the dynamic forcing functions is included as well. The process of performing a dynamic CLA of NASA hardware during marine transport is thought to be a first and can likely support minimization of undue conservatism.

Knight, J. Brent↗

NASA NTRS2017

Norton-Thevenin Receptance Coupling (NTRC) as a Payload Design Tool

The NASA Engineering and Safety Center (NESC) is funding a study to develop an alternate method for performing coupled loads analysis called Norton-Thevenin Receptance Coupling (NTRC). NTRC combines Receptance Coupling (RC), a frequency-domain synthesis method and Norton-Thevenin (NT) theory, an impedance based approach for simulating the interaction between dynamic systems. The goal of developing the NTRC method is to provide a tool that payload developers can use to reduce the conservatism in defining preliminary design loads, assess the impact of design changes between formal load cycles, and to perform trade studies for design optimization with a minimum amount of data required from the launch vehicle (LV) provider. NTRC also has the ability to perform parametric loads analysis where many different design configurations can be evaluated. This will result in cost and schedule benefits to the payload developer that are currently not possible under the standard coupled loads analysis (CLA) flow where typically only 2-3 official load cycles are performed by the LV provider over the life of a payload program. NTRC is not envisioned as a replacement for the official load cycles performed by the LV provider but rather as a means to address the types of design issues faced by the payload developer before and between official load cycles.The presentation provides an overview of the NTRC methodology and discusses how NTRC can be used to replicate the results from a standard LV CLA. The presentation covers the benchmarking that has been performed as part of the NESC study to demonstrate the accuracy of the technique for both frequency and time domain dynamic analyses. Future plans for benchmarking the NTRC approach against CLA results for NASAs Space Launch System (SLS) and commercial launch vehicles are discussed and the role that NTRC is envisioned to play in the payload development cycle.

Structural Dynamics↗

NASA NTRS2018

Norton-Thevenin Receptance Coupling (NTRC) as a Payload Analysis Tool

The NASA Engineering and Safety Center (NESC) has funded a study of a new method formulated by NASA Engineers called Norton-Thevenin Receptance Coupling (NTRC) to perform coupled loads analysis (CLA). The problem that NTRC attempts to solve is the dependency of the payload organization to high CLA costs, long schedules, lack of standard capabilities to evaluate multiple configurations and unavailability of loads when needed. NTRC solves the problem by providing a tool that payload developers can use to obtain loads at a fraction of the cost of a CLA at any time that it is required. While NTRC is not intended to replace the formal load cycles performed by the launch vehicle (LV) provider, it will provide the ability to reduce the conservatism in defining preliminary design loads, assess the impact of design changes between formal load cycles, perform trade studies and perform parametric loads analysis where many different design configurations can be evaluated with a minimum amount of data required from the LV provider. NTRC condenses all the necessary information into the launch vehicle to payload/s connection points or boundary degrees of freedom (BD). The launch vehicle model is represented by its impedance at its BDs; its forcing functions are represented by the acceleration at those BDs when the payload is absent and the latter is represented by its impedance at the same BDs. Payload responses are represented by transfer functions of selected response to interface BDs. The methodology has contributed to the Loads and Dynamics discipline advancement and successfully passed Peer Reviews. NTRC is exact in the frequency domain. Time domain replication and accuracy is outstanding. A second phase is envisioned to benchmark the whole set of CLA events for the Agency's most utilized Launch Vehicles, and ready it for operational deployment at NASA.

Kaufman, Daniel↗

NASA NTRSDate not supplied

Space Shuttle Cargo Integration Coupled Loads Analysis Lessons Learned

When a system experiences a loading environment characterized by rapidly varying forces, such as a rocket launch, a transient analysis is used to analyze the response of the system. The most common transient analysis methodology is the Coupled Loads Analysis(CLA). CLAs are used by the automotive and aerospace industry to analyze cars, trucks,planes, helicopters, spacecraft, etc. The Space Shuttle program used the CLA methodology to assess the compatibility of the payload with the Orbiter and the flight environment. The Space Shuttle Verification Loads Analysis (VLA) was a standardized CLA process that started between ten and thirteen months prior to launch, and included several meetings as well as analysis by both the Space Shuttle Program and the payload developers to verify that the payloads were compatible with the flight loads environment and would not interact negatively with the vehicle. Over the course of the Space Shuttle Program, many improvements were made to the process, which reduced cycle time and improved manifest flexibility. There were several issues which were never fully addressed, but work-arounds were developed to keep the process flowing. The lessons learned included automation of some processes and standardization of others, early assessments, improved documentation and better coordination with all stakeholders in the process. Lessons learned also included the limitations in the current process, and what to do to avoid the same issues.

ERICA E. BRUNO↗

NASA NTRSDate not supplied

Space Shuttle Cargo Integration Coupled Loads Analysis Lessons Learned

When a system experiences a loading environment characterized by rapidly varying forces, such as a rocket launch, a transient analysis is used to analyze the response of the system. The most common transient analysis methodology is the Coupled Loads Analysis (CLA). CLAs are used by the automotive and aerospace industry to analyze cars, trucks, planes, helicopters, spacecraft, etc. The Space Shuttle program used the CLA methodology to assess the compatibility of the payload with the Orbiter and the flight environment. The Space Shuttle Verification Loads Analysis (VLA) was a standardized CLA process that started between ten and thirteen months prior to launch, and included several meetings as well as analysis by both the Space Shuttle Program and the payload developers to verify that the payloads were compatible with the flight loads environment and would not interact negatively with the vehicle. Over the course of the Space Shuttle Program, many improvements were made to the process, which reduced cycle time and improved manifest flexibility. There were several issues which were never fully addressed, but workarounds were developed to keep the process flowing. The lessons learned included automation of some processes and standardization of others, early assessments, improved documentation and better coordination with all stakeholders in the process. Lessons learned also included the limitations in the current process, and what to do to avoid the same issues in the future.

Erica E. Bruno↗

NASA NTRSDate not supplied

A Flexible Multibody Approach to Space Launch System Liftoff Pad Separation with Umbilical Disconnect

Joel W Sills↗

NASA NTRSDate not supplied

A Flexible Multibody Framework for Space Launch System Liftoff with Umbilical Separations

ICPSU clearances to the lifting SLS vehicle were computed utilizing a coupled system nonlinear simulation approach in order to accurately capture the impact of system flexibilities, SLS forcing functions, pad separation (twang), ML dynamics and timings • i.e., integrate ICPSU model into a SLS nonlinear Coupled Loads Analysis (CLA) This required utilizing a flexible multibody framework for the CLA and the integration of large displacements/rotations capabilities into that CLA • Gantry rotation • Disconnect and retraction of flexible hoses

Arya Majed↗

NASA NTRSDate not supplied

Space Launch System Artemis I Ascent Loads Reconstruction Summary

On November 16, 2022, NASA successfully launched the Space Launch System (SLS) rocket and Orion spacecraft for the first SLS mission, Artemis 1. This first flight was outfitted with Developmental Flight Instrumentation (DFI) such as accelerometers, pressure sensors, and strain gauges. The DFI supports many post-flight activities, one of which is the ascent loads reconstruction effort. The integrated vehicle ascent loads spans both boost phase and Core phase and often produces the largest loads experienced by the vehicle during flight. One of the primary goals of the ascent loads reconstruction is to evaluate applicable Coupled Loads Analysis (CLA) design math models, assumptions, and analysis methodologies. To achieve this goal, all significant ascent subevents have been reconstructed through the use of flight data, reconstructed inputs, and existing CLA simulations. Resulting responses have been compared to available flight measurements. Additionally, reconstructed subevent loads were combined and compared to appropriate flight data and pre-flight predictions.

SLS↗