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At least 19 records

Unsteady environments and responses of the shuttle combined loads orbiter test

Both separate and combined wind tunnel and vibration shaker tests were conducted on two structural panels representative of the Shuttle orbiter in the NASA LaRC 8-foot transonic pressure tunnel (TPT) to determine the effects of combined loads on the thermal protection system (TPS). The primary objective of this test was to provide a combined full-scale load environment and realistic time history of the dynamic pressures, Mach numbers (through transonic), and dynamic structural responses of these panels. The panels were selected from orbiter locations where interactive load sources such as aerodynamic shock waves, turbulent boundary layers, strut-induced vorticity, and substrate deformation combined to provide high bonding loads between the TPS and the orbiter structure. The test panels for this program were highly instrumented with static and dynamic pressure gages, accelerometers, deflectometers, strain gages, Schileren and high-speed photography, and special instrumentation necessary to determine TPS/structure interface loads and tile motions. Two test specimens of each orbiter panel were utilized. Both were high-fidelity representations of the selected orbiter location. The first panel (calibration panel) for each test was utilized to calibrate the tunnel and shaker system as well as provide a data-gathering source for applied static and dynamic loads. The second panel (test panel) for each test was subjected to flight time exposures only so that TPS characteristics as a function of flight mission exposure could be determined. These tests were the last in a series that was suce6ssfully completed and necessary to certify the TPS prior to the first launching of the Shuttle.

P. H. Schuetz

Effect of orbital transfer loads on large platforms

A preliminary automated structural sizing procedure suitable for conceptual design and early tradeoff studies of large truss platforms configured for shuttle transportation to LEO is discussed as well as some orbital transfer design considerations. Platforms that are sized to withstand orbital transfer loads for the LEO to GEO maneuver are compared to platforms sized only for LEO application. It is concluded that for platforms supporting low mass distributed payloads, platform and strut frequency requirements are strong design drivers for LEO applications. The struts are found to be extremely slender, thinswalled, and of small diameter. If full advantage is to be taken of these minimum mass designs, a manufacturing capability must be developed for long straight struts. For platforms that are to be transferred from LEO to GEO in a deployed state, the orbital transfer loads become design drivers. However, even for an initial thrust-to-weight ratio equal to 0.1, a platform on the order of 100 m diameter appears packageable with its OTV in one shuttle flight, and larger platforms appear possible at lower thrust-to-weight ratios.

Walz, J. E.

Test and evaluate passive orbital disconnect struts (PODS 3)

The objectives of the Passive Orbital Disconnect Struts (PODS) test are to evaluate modal resonance of the PODS-III supports to obtain engineering data required for use of PODS-III on flight systems; determine possible performance improvements in large LO2/LH2 space applications. (1) Modal Vibration Tests. A modal resonance survey is performed on a set of six PODS-III struts assembled in a dewar simulator. The survey conditions simulate both launch and orbital loadings of the struts. The orbital load range spans a full to an empty tank. The frequencies surveyed cover the range consistent with Shuttle qualification requirements and the principal resonant modes of the strut system. (2) Benefit study. The benefit of using PODS-III supports on OTV and Space Station LO sub 2 and LH sub 2 reference tanks was compared to nondisconnect supports. Four LO sub 2 and LH sub 2 tanks were studied under various conditions: (1) holding the launch resonance at 35 Hz and varying the orbit resonance; (2) analyzing both full and emtpy tanks at launch; (3) varying orbit boundary temperaure; (4) varying the number of struts; (5) varying orbit times; and (6) using or not using vapor cooling.

Parmley, R. T.

Spacecraft on-orbit coupled loads analysis

A method is presented for coupled loads analysis of on-orbit spacecraft systems. Discrete models are coupled then reduced using the Craig-Bampton technique. Coupled system transient response is determined as well as substructure interface forces and center-of-gravity accelerations. Typical results are presented for a spacecraft system having three components and being subjected to rocket motor thrust.

Tinker, Michael L.

Design Feasibility Study of a Space Station Freedom Truss

Here, the focus is on the design and configuration feasibility of the short spacer for the Space Station Program in its launch configuration. The product of this study is being used by Rockwell International (Rocketdyne Division) as they continue their design concept of the current short spacer configuration. It is anticipated that the launch loads will dominate the on-orbit loads and dictate the design configuration of the short spacer. At the present time, the on-orbit loads have not been generated. The structural analysis discussed herein is based on the transient events derived from the Space Transportation System (STS) Interface Control Document (ICD). The transient loading events consist of liftoff loads, landing loads, and emergency landing loads. The quasi-static loading events have been neglected, since the magnitude of the acceleration factors are lower than the transient acceleration factors. The normal mode analyses presented herein are based on the most feasible configurations with acceptable stress ranges.

Armand, Sasan C.

A survey of load methodologies for shuttle orbiter payloads

Loads methods currently being used to design shuttle orbiter payloads are summarized. Methods used for the design of payloads launched by expendable launch vehicles are described in historical perspective. Experiences gained from expendable launch vehicle payloads are used to develop methodologies for the space shuttle orbiter payloads. The objectives for the development of a new methodology for the shuttle payloads are to reduce the cost and schedule for the payload load analysis by decoupling the payload analysis from the launch vehicle to the maximum extent possible. Methods are described for payload member load estimation or obtaining upper bounds for dynamic loads, as well as load prediction or calculating actual transient member load time histories.

Chen, J. C.

A survey of load methodologies for shuttle orbiter payloads

Loads methods currently being used to design planetary spacecraft to be launched on the shuttle orbiter are summarized. Experiences gained from expendable launch vehicle payloads are used to develop methodologies for the space shuttle orbiter payloads. The objectives for the development of a new methodology for the shuttle payloads are to reduce the cost and schedule for the payload load analysis by decoupling the payload analysis from the launch vehicle to the maximum extent possible. Methods are described for payload member load estimation or obtaining upper bounds for dynamic loads, as well as load prediction or calculating actual transient member load time histories.

Chen, J. C.

Foot Forces during Treadmill Exercise on the International Space Station

Exercise has been the primary countermeasure to combat musculoskeletal changes during the approximately 6 month missions to the International Space Station (ISS). However, these countermeasures have not been successful in preventing loss of bone mineral density in the spine and hip of astronauts. We examined lower extremity loading during typical bouts of on-orbit exercise performed by 4 ISS crew members on the ISS treadmill (TVIS) and during locomotor activities on earth (1g). In-shoe forces were monitored at 128Hz using force-measuring insoles placed inside the shoes of the exercising crewmember, stored temporarily on Flash cards, and down-linked via satellite for analysis. Custom software extracted peak forces from up to 30 minutes of locomotor activity. All on-orbit loading conditions for walking and running resulted in peak forces and impact loading rates that were significantly less than those measured in 1g. Typical single leg loads on-orbit in walking and running were 0.860 plus or minus 0.04 body weights (BW) and 1.339 plus or minus 0.07 BW compared to 1.2 plus or minus 0.036 BW and 2.36 plus or minus 0.07 BW in 1g BW respectively. These results indicate that typical exercise on the ISS treadmill does not generate 1g-like loading conditions. This may be partly responsible for the loss of bone mineral density that has been observed in these and other crew members. Since on-orbit treadmill exercise requires a restraining load to return the crew member to the treadmill surface, more studies are required to enable comfortable full body weight loading to be applied.

Cavanagh, Peter R.

Orbiter Landing Loads Math Model Description and Correlation with ALT Flight Data

Results of the space shuttle approach and landing test are examined in order to assess landing gear characteristics and performance and verify landing dynamic analyses. The landing gears were instrumented with load-calibrated strain gages, a wheel-speed sensor, and strut stroke measurement devices. The mathematical procedure used in predicting the shuttle touchdown loads and dynamics is presented together with the comparisons between measured flight data and the analytical predictions. Conclusions from these data are also presented.

Hamilton, D. A.

Development and Qualification of the Primary Structure of the Orion European Service Module

This paper presents an overview of the development and qualification test campaign for the primary structure of the European Service Module of ORION, the NASA spacecraft which will serve the future human exploration missions to the Moon, Mars and beyond. Under an agreement between NASA and ESA, the ORION will be powered by a European Service Module (ESM), providing also water and oxygen for astronauts' life sustainability. The development and qualification of the European Service Module (ESM) is under ESA responsibility with Airbus Defense and Space as the prime contractor. Thales Alenia Space Italia is responsible for design development, manufacturing, assembly and qualification of the Structure subsystem. The European Service Module, installed onto the launch adapter, shall support the crew module with its adapter and a launch abort system. It shall sustain: - A combination of global and local launch loads during lift off and ascent phases, - On orbit loads induced by engine firing for orbital transfers and attitude control. The ESM structure is based on a core made of Composite Fiber Reinforced Polymer (CFRP) sandwich panels complemented by aluminum alloy platforms, longerons and secondary structures. A development campaign has been implemented in order to define and validate composite parts' strength allowable values for design: coupon tests at material level, test at component level up to breadboards tests performed on main structural components (composite to metallic joints, and at panels' discontinuities). An incremental approach as defined in [1] has been followed. A qualification static test campaign at primary structure assembly level has been implemented in order to validate the design against static stiffness and ultimate strength as well as to correlate the structural Finite Element Model (FEM) used for sizing and confirm the margins of safety. The tests have been performed successfully by Thales Alenia Space Italia (TAS-I) on two flight representative structural models (STA1, STA2), in Turin facilities (Italy) between August 2015 and March 2017, with engineering support of technical representatives from Airbus, ESA, NASA and LMCO. The main development and qualification test activities and associated results are presented and discussed in the paper

Structural Testing

A superelement methodology for coupled loads analysis of Space Station Freedom

A technique for calculating the effects of on-orbit loads on the structural dynamics of the International Space Station is developed on the basis of MSC/NASTRAN superelement solution sequences. The complexity of the Space Station program with its multiple configurations, international partners, and contractors is stressed, and the impact of this complexity on the dynamic-load analysis process is indicated. The MSC/NASTRAN-based approach is outlined, and its application to two versions of the Permanent Manned Capability configuration is described in detail, including component mode synthesis, GFSC/FLAME coupled-loads analysis (with components from the system FEM model or from the Work Package), and ISI/MATRIX-X generation of closed-loop forcing functions. The results of these sample analyses are presented in extensive tables and graphs and briefly characterized.

Del Basso, Steve

NextSTEP Appendix A Modular ECLSS Effort Lessons Learned

NASA’s Artemis program provides the first steps for earth-independent exploration starting with crewed habitats in cislunar space and progressing toward crewed landings on the lunar surface that will prepare systems and crews for the exploration of Mars. The Next Space Technology for Exploration Partnerships (NextSTEP) is a public-private partnership model that facilitates commercial development of deep space exploration capabilities in support of more extensive human spaceflight missions in and beyond cislunar space. NASA issued the original NextSTEP Broad Agency Announcement (BAA) to U.S. industry in late 2014 and issued the second BAA (NextSTEP-2) in April 2016. The first appendix under NextSTEP-2, Appendix A, focused on developing deep space habitation concepts, engineering design and development, and risk reduction efforts leading to a habitation capability in cislunar space. NASA solicited concepts to develop and refine the evolvable, modular architecture, functional allocation options, standards, and common interfaces required to enable interoperability of the aggregate system to provide long duration deep space transit habitation, specifically enhancements and testing of deep space Environmental Control and Life Support Systems (ECLSS). Collins Aerospace, formerly UTC Aerospace Systems (UTAS), was awarded a Phase 1 and subsequent Phase 2 contract to “develop concepts that group ECLS systems into logical modules maximizing the use of common components and the development of unique methods and design concepts that support in-flight maintenance and repair for future exploration systems.” This paper summarizes the work accomplished under this effort, the lessons that can be applied to development of forthcoming habitation elements, and the gaps remaining to achieve a more resilient, maintainable, repairable and adaptable system capable of installation on a wide variety of habitat platforms. A primary accomplishment of this effort is the development and maturation of a modular palletization concept to enable standard rack interfaces, post-launch outfitting, and decoupling of structural supports that withstand launch environments from those needed for lower on-orbit loads in order to reduce installed mass and repurposing of panels within the habitat. In the course of the effort, Collins assessed numerous architecture trades, including the use of condensing and noncondensing heat exchangers, the ability of modular units to accommodate various habitat volumes and thermal loading, and the most appropriate order of and timing of delivery of regenerative ECLSS hardware to orbital habitats. In addition to the modularity of hardware elements, Collins developed software approaches for distributed/modular command, control, and communication systems and innovative Bayesian fault detection and isolation techniques. Finally, the effort explored advanced maintainability and supportability concepts including the definition of maintenance units (MUs) in place of the traditional Orbital Replacement Units (ORUs), increasing parts commonality to reduce the number and type of spare parts, the use of augmented reality to guide crews during maintenance and repair procedures, and how crews would prepare for and recover from long durations of habitat dormancy. Now that the NextSTEP Modular ECLSS effort has come to a close, it’s important to identify the lessons learned and where they can be leveraged to improve NASA’s broader program of ECLSS technology development and demonstration and ultimately how they can increase the performance of future surface and orbital habitats.

NextSTEP

NextSTEP Appendix A Modular ECLSS Effort Lessons Learned

NASA’s Artemis program provides the first steps for earth-independent exploration starting with crewed habitats in cislunar space and progressing toward crewed landings on the lunar surface that will prepare systems and crews for the exploration of Mars. The Next Space Technology for Exploration Partnerships (NextSTEP) is a public-private partnership model that facilitates commercial development of deep space exploration capabilities in support of more extensive human spaceflight missions in and beyond cislunar space. NASA issued the original NextSTEP Broad Agency Announcement (BAA) to U.S. industry in late 2014 and issued the second BAA (NextSTEP-2) in April 2016. The first appendix under NextSTEP-2, Appendix A, focused on developing deep space habitation concepts, engineering design and development, and risk reduction efforts leading to a habitation capability in cislunar space. NASA solicited concepts to develop and refine the evolvable, modular architecture, functional allocation options, standards, and common interfaces required to enable interoperability of the aggregate system to provide long duration deep space transit habitation, specifically enhancements and testing of deep space Environmental Control and Life Support Systems (ECLSS). Collins Aerospace, formerly UTC Aerospace Systems (UTAS), was awarded a Phase 1 and subsequent Phase 2 contract to “develop concepts that group ECLS systems into logical modules maximizing the use of common components and the development of unique methods and design concepts that support in-flight maintenance and repair for future exploration systems.” This paper summarizes the work accomplished under this effort, the lessons that can be applied to development of forthcoming habitation elements, and the gaps remaining to achieve a more resilient, maintainable, repairable and adaptable system capable of installation on a wide variety of habitat platforms. A primary accomplishment of this effort is the development and maturation of a modular palletization concept to enable standard rack interfaces, post-launch outfitting, and decoupling of structural supports that withstand launch environments from those needed for lower on-orbit loads in order to reduce installed mass and repurposing of panels within the habitat. In the course of the effort, Collins assessed numerous architecture trades, including the use of condensing and noncondensing heat exchangers, the ability of modular units to accommodate various habitat volumes and thermal loading, and the most appropriate order of and timing of delivery of regenerative ECLSS hardware to orbital habitats. In addition to the modularity of hardware elements, Collins developed software approaches for distributed/modular command, control, and communication systems and innovative Bayesian fault detection and isolation techniques. Finally, the effort explored advanced maintainability and supportability concepts including the definition of maintenance units (MUs) in place of the traditional Orbital Replacement Units (ORUs), increasing parts commonality to reduce the number and type of spare parts, the use of augmented reality to guide crews during maintenance and repair procedures, and how crews would prepare for and recover from long durations of habitat dormancy. Now that the NextSTEP Modular ECLSS effort has come to a close, it’s important to identify the lessons learned and where they can be leveraged to improve NASA’s broader program of ECLSS technology development and demonstration and ultimately how they can increase the performance of future surface and orbital habitats.

NextSTEP

Structures and mechanisms - Streamlining for fuel economy

The design of prospective NASA space station components which inherently possess the means for structural growth without compromising initial system characteristics is considered. In structural design terms, space station growth can be achieved by increasing design safety factors, introducing dynamic isolators to prevent loads from reaching the initial components, or preplanning the refurbishment of the original structure with stronger elements. Design tradeoffs will be based on the definition of on-orbit loads, including docking and maneuvering, whose derived load spectra will allow the estimation of fatigue life. Improvements must be made in structural materials selection in order to reduce contamination, slow degradation, and extend the life of coatings. To minimize on-orbit maintenance, long service life lubrication systems with advanced sealing devices must be developed.

Card, M. F.

Systems design and analysis of the microwave radiometer spacecraft

Systems design and analysis data were generated for microwave radiometer spacecraft concept using the Large Advanced Space Systems (LASS) computer aided design and analysis program. Parametric analyses were conducted for perturbations off the nominal-orbital-altitude/antenna-reflector-size and for control/propulsion system options. Optimized spacecraft mass, structural element design, and on-orbit loading data are presented. Propulsion and rigid-body control systems sensitivities to current and advanced technology are established. Spacecraft-induced and environmental effects on antenna performance (surface accuracy, defocus, and boresight off-set) are quantified and structured material frequencies and modal shapes are defined.

Garrett, L. B.

NASA's hypersonic fluid and thermal physics program (Aerothermodynamics)

This survey paper gives an overview of NASA's hypersonic fluid and thermal physics program (recently renamed aerothermodynamics). The purpose is to present the elements of, example results from, and rationale and projection for this program. The program is based on improving the fundamental understanding of aerodynamic and aerothermodynamic flow phenomena over hypersonic vehicles in the continuum, transitional, and rarefied flow regimes. Vehicle design capabilities, computational fluid dynamics, computational chemistry, turbulence modeling, aerothermal loads, orbiter flight data analysis, orbiter experiments, laser photodiagnostics, and facilities are discussed.

Graves, R. A.

Liquid flyback booster pre-phase: A study assessment

The concept of a flyback booster has been around since early in the shuttle program. The original two-stage shuttle concepts used a manned flyback booster. These boosters were eliminated from the program for funding and size reasons. The current shuttle uses two Redesigned Solid Rocket Motors (RSRM's), which are recovered and refurbished after each flight; this is one of the major cost factors of the program. Replacement options have been studied over the past ten years. The conclusion reached by the most recent study is that the liquid flyback booster (LFBB) is the only competitive option from a life-cycle cost perspective. The purpose of this study was to assess the feasibility and practicality of LFBB's. The study provides an expansion of the recommendations made during the aforementioned study. The primary benefits are the potential for enhanced reusability and a reduction of recurring costs. The potential savings in vehicle turnaround could offset the up-front costs. Development of LFBB's requires a commitment to the shuttle program for 20 to 30 years. LFBB's also offer enhanced safety and abort capabilities. Currently, any failure of an RSRM can be considered catastrophic, since there are no intact abort capabilities during the burn of the RSRM's. The performance goal of the LFBB's was to lift a fully loaded orbiter under optimal conditions, so as not to be the limiting factor of the performance capability of the shuttle. In addition, a final benefit is the availability of growth paths for applications other than shuttle.

Peterson, W.