Technology Roadmap for the Development of an Orbital Smallsat Factory
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Shuttle payload processing at KSC
Two basic systems of Shuttle payload and checkout are discussed. The first system is called 'off-line' checkout and checks out payloads or payload segments after they are brought to the launch complex laboratories, as individual units and transfer them to an integration facility where they are assembled into a total Shuttle payload. In this scheme all payload assembly and checkout is performed away from the Orbiter. Any problems concerning the payloads will allow rescheduling another payload for flight and therefore not subjecting the Orbiter to delays in its recycling flow. The second payload processing scheme is the 'on-line' checkout which employs a 'factory to pad' concept. Payloads are delivered directly to the pad, placed in the Payload Changeout Room where they are checked out and integrated and, after completion of servicing, are installed vertically into the Orbiter. A combination of off-line and on-line processing will be used to meet all flight requirements.
Phillips, J. D.↗
CIM's bridge from CADD to CAM: Data management requirements for manufacturing engineering
Manufacturing engineering represents the crossroads of technical data management in a Computer Integrated Manufacturing (CIM) environment. Process planning, numerical control programming and tool design are the key functions which translate information from as engineered to as assembled. In order to transition data from engineering to manufacturing, it is necessary to introduce a series of product interpretations which contain an interim introduction of technical parameters. The current automation of the product definition and the production process places manufacturing engineering in the center of CAD/CAM with the responsibility of communicating design data to the factory floor via a manufacturing model of the data. A close look at data management requirements for manufacturing engineering is necessary in order to establish the overall specifications for CADD output, CAM input, and CIM integration. The functions and issues associated with the orderly evolution of computer aided engineering and manufacturing are examined.
Ford, S. J.↗
Software for integrated manufacturing systems, part 1
For several years, a broad, unified approach to programming manufacturing cells, factory floors, and other manufacturing systems has been developed. It is based on a blending of distributed Ada, software components, generics and formal models. Among other things the machines and devices which make up the components, and the entire manufacturing cell is viewed as an assembly of software components. The purpose of this project is to reduce cost, increase the reliability and increase the flexibility of manufacturing software. An overview is given of the approach and an experimental generic factory floor controller that was developed using the approach is described. The controller is generic in the sense that it can control any one of a large class of factory floors making an arbitrary mix of parts.
Naylor, A. W.↗
America's Next Great Ship: Space Launch System Core Stage Transitioning from Design to Manufacturing
The Space Launch System (SLS) Program is essential to achieving the Nation's and NASA's goal of human exploration and scientific investigation of the solar system. As a multi-element program with emphasis on safety, affordability, and sustainability, SLS is becoming America's next great ship of exploration. The SLS Core Stage includes avionics, main propulsion system, pressure vessels, thrust vector control, and structures. Boeing manufactures and assembles the SLS core stage at the Michoud Assembly Facility (MAF) in New Orleans, LA, a historical production center for Saturn V and Space Shuttle programs. As the transition from design to manufacturing progresses, the importance of a well-executed manufacturing, assembly, and operation (MA&O) plan is crucial to meeting performance objectives. Boeing employs classic techniques such as critical path analysis and facility requirements definition as well as innovative approaches such as Constraint Based Scheduling (CBS) and Cirtical Chain Project Management (CCPM) theory to provide a comprehensive suite of project management tools to manage the health of the baseline plan on both a macro (overall project) and micro level (factory areas). These tools coordinate data from multiple business systems and provide a robust network to support Material & Capacity Requirements Planning (MRP/CRP) and priorities. Coupled with these tools and a highly skilled workforce, Boeing is orchestrating the parallel buildup of five major sub assemblies throughout the factory. Boeing and NASA are transforming MAF to host state of the art processes, equipment and tooling, the most prominent of which is the Vertical Assembly Center (VAC), the largest weld tool in the world. In concert, a global supply chain is delivering a range of structural elements and component parts necessary to enable an on-time delivery of the integrated Core Stage. SLS is on plan to launch humanity into the next phase of space exploration.
Birkenstock, Benjamin↗
NASA's Space Launch System Begins Integration, Stacking in Preparation for Artemis I Launch
The Artemis era of human lunar exploration is nearing take-off as NASA’s new super heavy-lift launch vehicle, the Space Launch System (SLS), begins stack-ing and integration operations in mid-2020 at Kennedy Space Center (KSC) in Florida. With a planned upgrade path to progressively more powerful vehicles and availability in crew and cargo configurations, SLS provides a unique and flexible launch solution to send crew, large-scale infrastructure and robotic probes to deep space. The SLS Block 1 vehicle, the initial variant to fly, is optimized for lunar missions with a proven propulsion system consisting of four liquid hydrogen (LH2)/liquid oxygen (LOX)-fed RS-25 engines and twin five-segment solid rocket boosters (SRBs). The Block 1 vehicle can also be outfitted with an industry-standard 5 m-class payload fairing (the “cargo” configuration) and will launch at least 27 metric tons (t) of mass to trans-lunar injection (TLI). SLS is the backbone of NASA’s Artemis program, which will return the agency’s human spaceflight program to the Moon for the first time since 1972. For the Artemis I mission, SLS will send an uncrewed Orion spacecraft to TLI, where it will enter a distant retrograde lunar orbit and fly 38,000 nmi past the Moon – farther than any spacecraft built for humans has ever traveled. The SLS Block 1 vehicle for Artemis I completed manufacturing in 2019. Several elements, including the upper stage, have been delivered to the Exploration Ground Systems (EGS) program at KSC and are being prepped for integration and stack-ing. The five-segment solid rocket boosters – the largest and most powerful ever built for flight – are also complete. The booster motor segments for the Artemis I flight are scheduled to ship from prime contractor Northrop Grumman’s Utah facilities and begin stacking and integration at KSC in June 2020. The SLS core stage is the largest rocket stage NASA has ever built in terms of volume and height, and includes the avionics and the tanks that feed cryogenic propellant to the four RS-25s (formerly Space Shuttle Main Engines [SSMEs]). They have been modified with an updated controller and nozzle insulation to protect them from the hotter launch environment. The SLS core stage is currently being test-ed at NASA’s Stennis Space Center (SSC) in a series of “green run” tests to verify it meets design and performance requirements. Following the green run test series, which is scheduled to culminate with a full-duration hot-fire of the four RS-25 engines, the core stage will ship to KSC and be stacked between the sol-id rocket boosters in the Vehicle Assembly Building (VAB). Integration of the vehicle will continue with the upper stage, known as the Interim Cryogenic Propulsion Stage (ICPS) and the Launch Vehicle Stage Adapter (LVSA) on the core stage. Another adapter, the Orion Stage Adapter (OSA), connects SLS to Orion and provides housing for 13 6U CubeSat payloads manifested on Artemis I. The CubeSats will be released in deep space after Orion separates from the vehicle, and the flight marks the first ride share opportunity for independent small-sats to deep space. The second major SLS variant to come online, Block 1B, replaces the single-engine ICPS with a four-engine LH2/LOX Exploration Upper Stage (EUS). This more powerful upper stage, along with other vehicle up-grades, will enable the Block 1B vehicle to launch 38-42 t to TLI, depending on crew or cargo configuration. The final evolution of the vehicle, Block 2, will onramp evolved solid rocket boosters to increase mass to TLI to 43-46 t, de-pending on crew or cargo configuration. The Block 1B/Block 2 vehicles can be outfitted with an 8.4 m-diameter payload fairing in 19.1 m or 27.4 m lengths, to provide unprecedented volume for payloads. With the initial Block 1 vehicle completely manufactured and the core stage in final testing before shipping to KSC, the SLS Program and its industry partners have made significant progress manufacturing subsequent vehicles. For the second Block 1 vehicle, the solid rocket motor segments are complete, as are the RS-25 engines with controllers. All five major components of the Artemis II core stage – the forward skirt, LOX and LH2 tanks, intertank and engine section – are manufactured and technicians are installing subsystems at NASA’s rocket factory, Michoud Assembly Facility. The RL-10 engine for the Artemis II ICPS is complete and panels have been machined for its LH2 tank. In addition, panels are machined for the vehicle’s two adapters, with welding scheduled to begin in summer 2020. Flight hard-ware is also in production for the third SLS vehicle, with several booster motor segments cast. The pace of development on the EUS has increased, with the goal to complete Critical Design Review (CDR) in December 2020. Several EUS test rings have been machined at Michoud. The EUS is designed to exe-cute a variety of missions – human spaceflight, deployment of deep-space infra-structure, or high-C3 missions to the outer solar system – with crew and cargo configurations available beginning in the mid-2020s. The near-term goal for the nation’s powerful new space exploration asset, however, is to launch the Arte-mis program, and send the first woman and the next man to the lunar surface. At the Astrodynamics Specialist Conference, the SLS program will update the community on the progress of the initial Block 1 vehicle in final green run test-ing, integration and stacking. In addition, this paper will provide an update to the community on the manufacturing status of subsequent Block 1 and Block 1B vehicles.
Steve Creech↗
PMR Graphite Engine Duct Development
The objective was to demonstrate the cost and weight advantages that could be obtained by utilizing the graphite/PMR15 material system to replace titanium in selected turbofan engine applications. The first component to be selected as a basis for evaluation was the outer bypass duct of the General Electric F404 engine. The operating environment of this duct was defined and then an extensive mechanical and physical property test program was conducted using material made by processing techniques which were also established by this program. Based on these properties, design concepts to fabricate a composite version of the duct were established and two complete ducts fabricated. One of these ducts was proof pressure tested and then run successfully on a factory test engine for over 1900 hours. The second duct was static tested to 210 percent design limit load without failure. An improved design was then developed which utilized integral composite end flanges. A complete duct was fabricated and successfully proof pressure tested. The net results of this effort showed that a composite version of the outer duct would be 14 percent lighter and 30 percent less expensive that the titanium duct. The other type of structure chosen for investigation was the F404 fan stator assembly, including the fan stator vanes. It was concluded that it was feasible to utilize composite materials for this type structure but that the requirements imposed by replacing an existing metal design resulted in an inefficient composite design. It was concluded that if composites were to be effectively used in this type structure, the design must be tailored for composite application from the outset.
Stotler, C. L.↗
Evolution of integrated panel structural design and interfaces for PV power plants
The evolution of integrated photovoltaic (PV) panel design at ARCO Solar is discussed. Historically, framed PV modules of about 1 x 4-ft size were individually mounted in the field on fixed support structures and interconnected electrically with cables to build higher-power arrays. When ARCO Solar saw the opportunity in 1982 to marry its PV modules with state-of-the-art heliostat trackers developed by ARCO Power Systems, it became obvious that mounting individual modules was impractical. For this project, the framed modules were factory-assembled into panels and interconnected with cables before being mounted on the trackers. Since then, ARCO Solar made considerable progress and gained substantial experience in the design and fabrication of large PV panels. Constraints and criteria considered in these design activities included static and dynamic loads; assembly and transportation equipment and logistics, structural and electrical interfaces, and safety and grounding concerns.
Arnett, J. C.↗
The International Orion Spacecraft Is off Towards the Stars
Following a very successful year of manufacturing, assembly and testing in factories located around the globe, NASA and ESA are preparing to deliver the major Exploration Mission-1 (EM-1) Orion flight elements, including the Crew Module, ESA Service Module and Launch Abort System. This international effort to design and develop a deep space exploration capable human spacecraft is rapidly transitioning from the design, development and test phase to the early test flight and production phase. Two major flight tests, an Ascent Abort test and EM-1, Orion's first flight onboard NASA's new heavy lift Space Launch System, are planned for the near future. Further, Orion will play a crucial role in the ambitious new Deep Space Gateway human exploration Program. This paper gives a short overview of the system and subsystem configuration of the Orion spacecraft, including NASA and ESA contributions, a status of EM-1, AA-2 and EM-2 spacecraft production, and a look at Orion's role in the construction and operation of the Deep Space Gateway. The paper will also address the innovative international cooperation methods being employed to conduct Orion and Service Module integration.
Kirasich, Mark↗
Simple, Scalable, Script-Based Science Processor (S4P)
The development and deployment of data processing systems to process Earth Observing System (EOS) data has proven to be costly and prone to technical and schedule risk. Integration of science algorithms into a robust operational system has been difficult. The core processing system, based on commercial tools, has demonstrated limitations at the rates needed to produce the several terabytes per day for EOS, primarily due to job management overhead. This has motivated an evolution in the EOS Data Information System toward a more distributed one incorporating Science Investigator-led Processing Systems (SIPS). As part of this evolution, the Goddard Earth Sciences Distributed Active Archive Center (GES DAAC) has developed a simplified processing system to accommodate the increased load expected with the advent of reprocessing and launch of a second satellite. This system, the Simple, Scalable, Script-based Science Processor (S42) may also serve as a resource for future SIPS. The current EOSDIS Core System was designed to be general, resulting in a large, complex mix of commercial and custom software. In contrast, many simpler systems, such as the EROS Data Center AVHRR IKM system, rely on a simple directory structure to drive processing, with directories representing different stages of production. The system passes input data to a directory, and the output data is placed in a "downstream" directory. The GES DAAC's Simple Scalable Script-based Science Processing System is based on the latter concept, but with modifications to allow varied science algorithms and improve portability. It uses a factory assembly-line paradigm: when work orders arrive at a station, an executable is run, and output work orders are sent to downstream stations. The stations are implemented as UNIX directories, while work orders are simple ASCII files. The core S4P infrastructure consists of a Perl program called stationmaster, which detects newly arrived work orders and forks a job to run the appropriate executable (registered in a configuration file for that station). Although S4P is written in Perl, the executables associated with a station can be any program that can be run from the command line, i.e., non-interactively. An S4P instance is typically monitored using a simple Graphical User Interface. However, the reliance of S4P on UNIX files and directories also allows visibility into the state of stations and jobs using standard operating system commands, permitting remote monitor/control over low-bandwidth connections. S4P is being used as the foundation for several small- to medium-size systems for data mining, on-demand subsetting, processing of direct broadcast Moderate Resolution Imaging Spectroradiometer (MODIS) data, and Quick-Response MODIS processing. It has also been used to implement a large-scale system to process MODIS Level 1 and Level 2 Standard Products, which will ultimately process close to 2 TB/day.
Lynnes, Christopher↗