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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2019

Dynamic Characterization of the Crew Module Uprighting System for NASA’s Orion Crew Module

The Orion Crew Module Uprighting System is a set of five airbag that are responsible for the uprighting of the crew module in the case of an inverted splashdown. A series of tests during the Underway Recovery Test 7 (URT-7) were run in preparation for the Artemis I mission, where the dynamic characterization of the CMUS in an ocean wave environment was performed. A Datawell Waverider DWR-G4 wave buoy was deployed to the characterize the wave environment during these tests. The heave measurements from this buoy were projected to the Orion Crew Module Buoyancy Test Article location by two different methods: (1) directly time-shifting the data, and (2) performing a frequency-domain, phase-shifting operation. Results demonstrate that the phase-shifting operation led to better correlation with the true crew module response to wave excitation as compared with the purely time-shifted method. Additionally, a novel approach to localize an object in a bidirectional wave field based on its heave response is presented and validated with URT- 7 data. Given a wave measurement device at a known location, one can estimate the relative distance to another object based solely off its heave response. Results show that if signals have sufficiently good correlation, this method can be used to estimate the relative separation between two objects in the same wave field.

Vertaska, Ivan Bertaska↗
NASA NTRS2011

Assessment of an Automated Touchdown Detection Algorithm for the Orion Crew Module

Orion Crew Module (CM) touchdown detection is critical to activating the post-landing sequence that safe?s the Reaction Control Jets (RCS), ensures that the vehicle remains upright, and establishes communication with recovery forces. In order to accommodate safe landing of an unmanned vehicle or incapacitated crew, an onboard automated detection system is required. An Orion-specific touchdown detection algorithm was developed and evaluated to differentiate landing events from in-flight events. The proposed method will be used to initiate post-landing cutting of the parachute riser lines, to prevent CM rollover, and to terminate RCS jet firing prior to submersion. The RCS jets continue to fire until touchdown to maintain proper CM orientation with respect to the flight path and to limit impact loads, but have potentially hazardous consequences if submerged while firing. The time available after impact to cut risers and initiate the CM Up-righting System (CMUS) is measured in minutes, whereas the time from touchdown to RCS jet submersion is a function of descent velocity, sea state conditions, and is often less than one second. Evaluation of the detection algorithms was performed for in-flight events (e.g. descent under chutes) using hi-fidelity rigid body analyses in the Decelerator Systems Simulation (DSS), whereas water impacts were simulated using a rigid finite element model of the Orion CM in LS-DYNA. Two touchdown detection algorithms were evaluated with various thresholds: Acceleration magnitude spike detection, and Accumulated velocity changed (over a given time window) spike detection. Data for both detection methods is acquired from an onboard Inertial Measurement Unit (IMU) sensor. The detection algorithms were tested with analytically generated in-flight and landing IMU data simulations. The acceleration spike detection proved to be faster while maintaining desired safety margin. Time to RCS jet submersion was predicted analytically across a series of simulated Orion landing conditions. This paper details the touchdown detection method chosen and the analysis used to support the decision.

Gay, Robert S.↗
NASA NTRS2017

Spacecraft Charging Considerations and Design Efforts for the Orion Crew Module

The Orion Crew Module (CM) is nearing completion for the next flight, designated as Exploration Mission 1 (EM-1). For the uncrewed mission, the flight path will take the CM through a Perigee Raise Maneuver (PRM) out to an altitude of approximately 1800 km, followed by a Trans-Lunar Injection burn, a pass through the Van Allen belts then out to the moon for a lunar flyby, a Distant Retrograde Insertion (DRI) burn, a Distant Retrograde Orbit (DRO), a Distant Retrograde Departure (DRD) burn, a second lunar flyby, an Earth Insertion (EI) burn, and finally entry and landing. All of this, with the exception of the DRO associated maneuvers, is similar to the previous Apollo 8 mission in late 1968. In recent discussions, it is now possible that EM-1 will be a crewed mission, and if this happens, the orbit may be quite different from that just described. In this case, the flight path may take the CM on an out and back pass through the Van Allen belts twice, then out to the moon, again passing through the Van Allen belts twice, then finally back home. Even if the current EM-1 mission doesn't end up as a crewed mission, EM-2 and subsequent missions will undoubtedly follow orbital trajectories that offer comparable exposures to heightened vehicle charging effects. Because of this, and regardless of flight path, the CM vehicle will likely experience a wide range of exposures to energetic ions and electrons, essentially covering the gamut between low earth orbit to geosynchronous orbit and beyond. National Aeronautical and Space Administration (NASA) and Lockheed Martin (LM) engineers and scientists have been working to fully understand and characterize the vehicle's immunity level with regard to surface and deep dielectric charging, and the ramifications of that immunity level pertaining to materials and impacts to operational avionics, communications, and navigational systems. This presentation attempts to chronicle these efforts in a summary fashion, and attempts to capture the results of that work as they pertain to the electrical and avionic systems on-board the Orion CM.

Scully, Bob↗
NASA NTRS2009

Developing NDE Techniques for Orion Crew Module

Project: The Orion Crew Module (CM) and Service Module (SM) subsystems will require approximately 870 tube welds to be fabricated onsite at KSC O&C High Bay. A quick and reliable NDE technique is required to ensure efficient assembly and superior weld quality.

Parker, Don↗
NASA NTRS2008

Airbag Landing Impact Performance Optimization for the Orion Crew Module

This report will discuss the use of advanced simulation techniques to optimize the performance of the proposed Orion Crew Module airbag landing system design. The Boeing Company and the National Aeronautic and Space Administration s Langley Research Center collaborated in the analysis of the proposed airbag landing system for the next generation space shuttle replacement, the Orion spacecraft. Using LS-DYNA to simulate the Crew Module landing impacts, two main objectives were established and achieved: the investigation of potential methods of optimizing the airbag performance in order to reduce rebound on the anti-bottoming bags, lower overall landing loads, and increase overall Crew Module stability; and the determination of the Crew Module stability and load boundaries using the optimized airbag design, based on the potential Crew Module landing pitch angles and ground slopes in both the center of gravity forward and aft configurations. This paper describes the optimization and stability and load boundary studies and presents a summary of the results obtained and key lessons learned from this analysis.

Lee, Timothy J.↗
NASA NTRS2008

Evaluation of a Seat Attenuation System for the Orion Crew Module

The function of the crew seat attenuation system for the Orion Crew Module (CM) is to provide the crew with a low injury-risk landing environment under a range of crew configurations and landing conditions. The current design for the seat attenuation system provides the crew with a low risk of injury environment based on the Brinkley criteria for most of the landing conditions considered. Furthermore, the stroking of the seat attenuation system is within limits, and the clearance between the seat support platform and vehicle is not exceeded. For the limited number of landing conditions where a low injury risk is exceeded, the risk is never beyond a moderate level. The results presented in this study are based on a CM structural model that is rigid except for the pallet struts, which attenuate landing loads and reduce the accelerations transferred to the astronauts. The CM simulations include a soft soil landing. Several different crew configurations are evaluated in this study. It is expected that situations where the risk is above low can be eliminated in future design iterations.

Lawrence, Charles↗
NASA NTRS2010

Orion Pad Abort 1 Crew Module Inertia Test Approach and Results

The Flight Loads Laboratory at the Dryden Flight Research Center conducted tests to measure the inertia properties of the Orion Pad Abort 1 (PA-1) Crew Module. These measurements were taken to validate analytical predictions of the inertia properties of the vehicle and assist in reducing uncertainty for derived aero performance results calculated post launch. The first test conducted was to determine the Ixx of the Crew Module. This test approach used a modified torsion pendulum test step up that allowed the suspended Crew Module to rotate about the x axis. The second test used a different approach to measure both the Iyy and Izz properties. This test used a Knife Edge fixture that allowed small rotation of the Crew Module about the y and z axes. Discussions of the techniques and equations used to accomplish each test are presented. Comparisons with the predicted values used for the final flight calculations are made. Problem areas, with explanations and recommendations where available, are addressed. Finally, an evaluation of the value and success of these techniques to measure the moments of inertia of the Crew Module is provided.

Herrera, Claudia↗
NASA NTRS2012

Orion Pad Abort 1 Crew Module Mass Properties Test Approach and Results

The Flight Loads Laboratory at the Dryden Flight Research Center conducted tests to measure the inertia properties of the Orion Pad Abort 1 (PA-1) Crew Module (CM). These measurements were taken to validate analytical predictions of the inertia properties of the vehicle and assist in reducing uncertainty for derived aero performance coefficients to be calculated post-launch. The first test conducted was to determine the Ixx of the Crew Module. This test approach used a modified torsion pendulum test setup that allowed the suspended Crew Module to rotate about the x axis. The second test used a different approach to measure both the Iyy and Izz properties. This test used a Knife Edge fixture that allowed small rotation of the Crew Module about the y and z axes. Discussions of the techniques and equations used to accomplish each test are presented. Comparisons with the predicted values used for the final flight calculations are made. Problem areas, with explanations and recommendations where available, are addressed. Finally, an evaluation of the value and success of these techniques to measure the moments of inertia of the Crew Module is provided.

Herrera, Claudia↗
NASA NTRS2014

Design, Integration, Certification and Testing of the Orion Crew Module Propulsion System

The Orion Crew Module Propulsion Reaction Control System is currently complete and ready for flight as part of the Orion program's first flight test, Exploration Flight Test One (EFT-1). As part of the first article design, build, test, and integration effort, several key lessons learned have been noted and are planned for incorporation into the next build of the system. This paper provides an overview of those lessons learned and a status on the Orion propulsion system progress to date.

McKay, Heather↗
NASA NTRS2014

Orion Crew Module / Service Module Structural Weight and Center of Gravity Simulator and Vehicle Motion Simulator Hoist Structure for Orion Service Module Umbilical Testing

An Orion Crew Module Service Module Structural Weight and Center of Gravity Simulator and a Vehicle Motion Simulator Hoist Structure for Orion Service Module Umbilical Testing were designed during a summer 2014 internship in Kennedy Space Centers Structures and Mechanisms Design Branch. The simulator is a structure that supports ballast, which will be integrated into an existing Orion mock-up to simulate the mass properties of the Exploration Mission-1 flight vehicle in both fueled and unfueled states. The simulator mimics these configurations through the use of approximately 40,000 lbf of steel and water ballast, and a steel support structure. Draining four water tanks, which house the water ballast, transitions the simulator from the fueled to unfueled mass properties. The Ground Systems Development and Operations organization will utilize the simulator to verify and validate equipment used to maneuver and transport the Orion spacecraft in its fueled and unfueled configurations. The second design comprises a cantilevered tripod hoist structure that provides the capability to position a large Orion Service Module Umbilical in proximity to the Vehicle Motion Simulator. The Ground Systems Development and Operations organization will utilize the Vehicle Motion Simulator, with the hoist structure attached, to test the Orion Service Module Umbilical for proper operation prior to installation on the Mobile Launcher. Overall, these two designs provide NASA engineers viable concepts worthy of fabricating and placing into service to prepare for the launch of Orion in 2017.

VMS↗
NASA NTRS2013

Ballistics Analysis of Orion Crew Module Separation Bolt Cover

NASA is currently developing a new crew module to replace capabilities of the retired Space Shuttles and to provide a crewed vehicle for exploring beyond low earth orbit. The crew module is a capsule-type design, which is designed to separate from the launch vehicle during launch ascent once the launch vehicle fuel is expended. The separation is achieved using pyrotechnic separation bolts, wherein a section of the bolt is propelled clear of the joint at high velocity by an explosive charge. The resulting projectile must be contained within the fairing structure by a containment plate. This paper describes an analytical effort completed to augment testing of various containment plate materials and thicknesses. The results help guide the design and have potential benefit for future similar applications.

Howard, Samuel A.↗
NASA NTRSDate not supplied

Modeling Uprighting of the Orion Crew Module using a Finite Element Method with Wave Coupling and Structural Deformability

The Crew Module Uprighting System (CMUS) for the Orion Crew Module (CM) includes five bags that inflate after splashdown to rotate and upright the CM as necessary. Wave conditions can be severe enough to damage the bags and tethers, which could make the recovery operation hazardous. The CMUS therefore has design limits that ultimately constrain where the CM can land based upon sea conditions. This manuscript describes a full fluid-structure interaction computational model being used for the CMUS. It is a finite element model that uses explicit time integration to directly simulate uprighting, a computational approach usually reserved for short duration, highly transient phenomena and novelly applied here. The goal of this current effort is to determine the feasibility of this approach for CMUS uprighting, and to estimate the loads the CMUS bags experience in different wave conditions. The results from this work will be used to supplement other experimental and computational data in support of NASA’s Artemis program.

John Puryear↗
NASA NTRS2000

A Human Factors Evaluation of a Methodology for Pressurized Crew Module Acceptability for Zero-Gravity Ingress of Spacecraft

This project aimed to develop a methodology for evaluating performance and acceptability characteristics of the pressurized crew module volume suitability for zero-gravity (g) ingress of a spacecraft and to evaluate the operational acceptability of the NASA crew return vehicle (CRV) for zero-g ingress of astronaut crew, volume for crew tasks, and general crew module and seat layout. No standard or methodology has been established for evaluating volume acceptability in human spaceflight vehicles. Volume affects astronauts'ability to ingress and egress the vehicle, and to maneuver in and perform critical operational tasks inside the vehicle. Much research has been conducted on aircraft ingress, egress, and rescue in order to establish military and civil aircraft standards. However, due to the extremely limited number of human-rated spacecraft, this topic has been un-addressed. The NASA CRV was used for this study. The prototype vehicle can return a 7-member crew from the International Space Station in an emergency. The vehicle's internal arrangement must be designed to facilitate rapid zero-g ingress, zero-g maneuverability, ease of one-g egress and rescue, and ease of operational tasks in multiple acceleration environments. A full-scale crew module mockup was built and outfitted with representative adjustable seats, crew equipment, and a volumetrically equivalent hatch. Human factors testing was conducted in three acceleration environments using ground-based facilities and the KC-135 aircraft. Performance and acceptability measurements were collected. Data analysis was conducted using analysis of variance and nonparametric techniques.

Sanchez, Merri J.↗
NASA NTRS2011

Development of the Orion Crew Module Static Aerodynamic Database: Supersonic/Subsonic - Par 2

This work describes the process of developing the nominal static aerodynamic coefficients and associated uncertainties for the Orion Crew Module for Mach 8 and below. The database was developed from wind tunnel test data and computational simulations of the smooth Crew Module geometry, with no asymmetries or protuberances. The database covers the full range of Reynolds numbers seen in both entry and ascent abort scenarios. The basic uncertainties were developed as functions of Mach number and total angle of attack from variations in the primary data as well as computations at lower Reynolds numbers, on the baseline geometry, and using different flow solvers. The resulting aerodynamic database represents the Crew Exploration Vehicle Aerosciences Project's best estimate of the nominal aerodynamics for the current Crew Module vehicle.

Bibb, Karen L.↗
NASA NTRS2014

Design, Integration, Certification and Testing of the Orion Crew Module Propulsion System

The Orion Multipurpose Crew Vehicle (MPCV) is NASA's next generation spacecraft for human exploration of deep space. Lockheed Martin is the prime contractor for the design, development, qualification and integration of the vehicle. A key component of the Orion Crew Module (CM) is the Propulsion Reaction Control System, a high‐flow hydrazine system used during re‐entry to orient the vehicle for landing. The system consists of a completely redundant helium (GHe) pressurization system and hydrazine fuel system with monopropellant thrusters. The propulsion system has been designed, integrated, and qualification tested in support of the Orion program's first orbital flight test, Exploration Flight Test One (EFT‐1), scheduled for 2014. A subset of the development challenges and lessons learned from this first flight test campaign will be discussed in this paper for consideration when designing future spacecraft propulsion systems. The CONOPS and human rating requirements of the CM propulsion system are unique when compared with a typical satellite propulsion reaction control system. The system requires a high maximum fuel flow rate. It must operate at both vacuum and sea level atmospheric pressure conditions. In order to meet Orion's human rating requirements, multiple parts of the system must be redundant, and capable of functioning after spacecraft system fault events.

McKay, Heather↗
NASA NTRS2013

Composite Crew Module (CCM) Permeability Characterization

In January 2007, the NASA Administrator chartered the NASA Engineering and Safety Center (NESC) to form an Agency team to design and build a composite crew module in 18 months in order to gain hands-on experience in anticipation that future exploration systems may be made of composite materials. One of the conclusions from this Composite Crew Module Primary Structure assessment was that there was a lack of understanding regarding the ability for composite pressure shells to contain consumable gases, which posed a technical risk relative to the use of a metallic design. After the completion of the Composite Crew Module test program, the test article was used in a new program to assess the overall leakage/permeability and identify specific features associated with high leak rates. This document contains the outcome of the leakage assessment.

Kirsch, Michael T.↗
NASA NTRS1985

Design and testing of an energy-absorbing crewseat for the F/FB-111 aircraft. Volume 3: Data from crew module testing

Over the past years, several papers and reports have documented the unacceptably high injury rate during the escape sequence (including the ejection and ground impact) of the crew module for F/FB-111 aircraft. This report documents a program to determine if the injury potential could be reduced by replacing the existing crewseats with energy absorbing crewseats. An energy absorbing test seat was designed using much of the existing seat hardware. An extensive dynamic seat test series, designed to duplicate various crew module ground impact conditions, was conducted at a sled test facility. Comparative tests with operational F-111 crewseats were also conducted. After successful dynamic testing of the seat, more testing was conducted with the seats mounted in an F-111 crew module. Both swing tests and vertical drop tests werre conducted. The vertical drop tests were used to obtain comparative data between the energy absorbing and operational seats.

Shane, S. J.↗
NASA NTRS2018

ORION - Crew Module Side Hatch: Proof Pressure Test Anomaly Investigation

The Orion Multi-Purpose Crew Vehicle program was performing a proof pressure test on an engineering development unit (EDU) of the Orion Crew Module Side Hatch (CMSH) assembly. The purpose of the proof test was to demonstrate structural capability, with margin, at 1.5 times the maximum design pressure, before integrating the CMSH to the Orion Crew Module structural test article for subsequent pressure testing. The pressure test was performed at lower pressures of 3 psig, 10 psig and 15.75 psig with no apparent abnormal behavior or leaking. During pressurization to proof pressure of 23.32 psig, a loud 'pop' was heard at ~21.3 psig. Upon review into the test cell, it was noted that the hatch had prematurely separated from the proof test fixture, thus immediately ending the test. The proof pressure test was expected be a simple verification but has since evolved into a significant joint failure investigation from both Lockheed Martin and NASA.

Evernden, Brent A.↗