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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

Modular space station, phase B extension. Information management advanced development. Volume 4: Data processing assembly

The computation and logical functions which are performed by the data processing assembly of the modular space station are defined. The subjects discussed are: (1) requirements analysis, (2) baseline data processing assembly configuration, (3) information flow study, (4) throughput simulation, (5) redundancy study, (6) memory studies, and (7) design requirements specification.

Gerber, C. R.↗

Life Testing of the Vapor Compression Distillation Urine Processing Assembly (VCD/UPA) at the Marshall Space Flight Center

Wastewater and urine generated on the International Space Station will be processed to recover pure water. The method selected is vapor compression distillation (VCD). To verify the long-term reliability and performance of the VCD Urine Processing Assembly (UPA), accelerated life testing was performed at the Marshall Space Flight Center (MSFC) from January 1993 to April 1996. Two UPAS, the VCD-5 and VCD-5A, were tested for 204 days and 665 days, respectively. The compressor gears and the distillation centrifuge drive belt were found to have an operating life of approximately 4800 hours. Precise alignment of the flex-spline of the fluids pump is essential to avoid failure of the pump after about 400 hours of operation. Also, leakage around the seals of the drive shaft of the fluids pump and purge pump must be eliminated for continued good performance. Results indicate that, with some design and procedural modifications and suitable quality control, the required performance and operational life can be met with the VCD/UPA.

Wieland, Paul O.↗

Ground Test of the Urine Processing Assembly for Accelerations and Transfer Functions

This viewgraph presentation gives an overview of the ground test of the urine processing assembly for accelerations and transfer functions. Details are given on the test setup, test data, data analysis, analytical results, and microgravity assessment. The conclusions of the tests include the following: (1) the single input/multiple output method is useful if the data is acquired by tri-axial accelerometers and inputs can be considered uncorrelated; (2) tying coherence with the matrix yields higher confidence in results; (3) the WRS#2 rack ORUs need to be isolated; (4) and future work includes a plan for characterizing performance of isolation materials.

Houston, Janice↗

Design and Assembly Process Implementation for Embedding Passive and Active Components Introduction to IPC-7092

"This presentation describes the design and assembly challenges for implementing passive and active components, in either formed or inserted methodology, into a printed board. The completed structure including internal electronic components is ready for surface mount and/or through-hole component attachment. The multilayered structure becomes a complete product ready for further processing in an assembly process and be made from organic, inorganic (ceramic) or both types of material."

embedded circuitry↗

Analog Processing Assembly for the Wake Vortex Lidar Experiment

The Federal Aviation Administration (FAA) and NASA have initiated a joint study in the development of reliable means of tracking, detecting, measuring, and predicting trailing wake-vortices of commercial aircraft. Being sought is an accurate model of the wake-vortex hazard, sufficient to increase airport capacity by reducing minimum safe spacings between planes. Several means of measurement are being evaluated for application to wake-vortex detection and tracking, including Doppler RADAR (Radio Detection and Ranging) systems, 2-micron Doppler LIDAR (Light Detection And Ranging) systems, and SODAR (Sound Detection And Ranging) systems. Of specific interest there is the lidar system, which has demonstrated numerous valuable capabilities as a vortex sensor Aerosols entrained in the vortex flow make the wake velocity signature visible to the lidar, (the observable lidar signal is essentially a measurement of the line-of-sight velocity of the aerosols). Measurement of the occurrence of a wake vortex requires effective reception and monitoring of the beat signal which results from the frequency-offset between the transmitted pulse and the backscattered radiation. This paper discusses the mounting, analysis, troubleshooting, and possible use of an analog processing assembly designed for such an application.

Stowe, Edwood G.↗

Life Testing of the Vapor Compression Distillation/Urine Processing Assembly (VCD/UPA) at the Marshall Space Flight Center (1993 to 1997)

Wastewater and urine generated on the International Space Station will be processed to recover pure water using vapor compression distillation (VCD). To verify the long-term reliability and performance of the VCD Urine Processor Assembly (UPA), life testing was performed at the Marshall Space Flight Center (MSFC) from January 1993 to April 1996. Two UPA'S, the VCD-5 and VCD-5A, were tested for 204 days and 665 days, respectively. The compressor gears and the distillation centrifuge drive belt were found to have operating lives of approximately 4,800 hours, equivalent to 3.9 years of operation on ISS for a crew of three at an average processing rate of 1.76 kg/h (3.97 lb/h). Precise alignment of the flex-splines of the fluids and purge pump motor drives is essential to avoid premature failure after about 400 hours of operation. Results indicate that, with some design and procedural modifications and suitable quality control, the required performance and operational life can be met with the VCD/UPA.

Wieland, P.↗

Synthesis of Large Molecules in Cometary Ice Analogs: Physical Properties Related to Self-Assembly Processes

The combination of realistic laboratory simulations and infrared observations have revolutionized our understanding of interstellar dust and ice-the main component of comets. Since comets and carbonaceous micrometeorites may have been important sources of volatiles and carbon compounds on the early Earth, their organic composition may be related to the origin of life. Ices on grains in molecular clouds contain a variety of simple molecules. The D/H ratios of the comets Hale-Bopp and Hyakutake are consistent with a primarily interstellar ice mixture. Within the cloud and especially in the presolar nebula through the early solar system, these icy grains would have been photoprocessed by the ultraviolet producing more complex species such as hexamethylenetetramine, polyoxymethylenes, and simple keones. We reported at the 1999 Bioastronomy meeting laboratory simulations studied to identify the types of molecules which could have been generated in pre-cometary ices. Experiments were conducted by forming a realistic interstellar mixed-molecular ice (H2O, CH3OH, NH3 and CO) at approximately 10 K under high vacuum irradiated with UV light from a hydrogen plasma lamp. The gas mixture was typically 100:50:1:1, however when different ratios were used material with similar characteristics was still produced. The residue that remained after warming to room temperature was analyzed by HPLC, and by several mass spectrometric methods. This material contains a rich mixture of complex compounds with mass spectral profiles resembling those found in IDPs and meteorites. Surface tension measurements show that an amphiphilic component is also present. These species do not appear in various controls or in unphotolyzed samples. Residues from the simulations were also dispersed in aqueous media for microscopy. The organic material forms 10-40 gm diameter droplets that fluoresce at 300-450 nm under UV excitation. These droplets have a morphology and internal structure which appear strikingly similar to those produced by extracts of the Murchison meteorite. Together, these results suggest a link between organic material photochemically synthesized on the cold grains in dense, interstellar molecular clouds and compounds that may have contributed to the organic inventory of the primitive Earth. For example, the amphiphilic properties of such compounds permit self-assembly into the membranous boundary structures that required for the first forms of cellular life.

Dworkin, Jason P.↗

Three-dimensional cell to tissue assembly process

The present invention relates a 3-dimensional cell to tissue and maintenance process, more particularly to methods of culturing cells in a culture environment, either in space or in a gravity field, with minimum fluid shear stress, freedom for 3-dimensional spatial orientation of the suspended particles and localization of particles with differing or similar sedimentation properties in a similar spatial region.

Wolf, David A.↗

Process and assembly plans for low cost commercial fuselage structure

Cost and weight reduction for a composite structure is a result of selecting design concepts that can be built using efficient low cost manufacturing and assembly processes. Since design and manufacturing are inherently cost dependent, concurrent engineering in the form of a Design-Build Team (DBT) is essential for low cost designs. Detailed cost analysis from DBT designs and hardware verification must be performed to identify the cost drivers and relationships between design and manufacturing processes. Results from the global evaluation are used to quantitatively rank design, identify cost centers for higher ranking design concepts, define and prioritize a list of technical/economic issues and barriers, and identify parameters that control concept response. These results are then used for final design optimization.

Willden, Kurtis↗

Gas Turbine Engine Carbon Oil Seals Computerized Assembly

In a bearing compartment there are a series of parts when assembled determine the location of the bearing and seal as related to the centerline of rotation. We see part datums that do not establish A coincident path from the bearing to the seal. High engine vibration can cause severe oil leakage. The inability of the seal to respond fast enough to the rotating element Radial Seal: Sensitive to housing air pressure Sensitive to seal runout ? Axial Seal: Very sensitive to seal perpendicularity to shaft. Goals include: 1) Repeatable assembly process; 2) Accurate assembly process; 3) Minimize seal runout; 4) Design to engine centerline of rotation, i.e. bearings.

Lee, Robert↗

Reliability of CCGA 1152 and CCGA 1272 Interconnect Packages for Extreme Thermal Environments

Ceramic column grid array (CCGA) packages have been increasing in use based on their advantages of high interconnect density, very good thermal and electrical performance, and compatibility with standard surface-mount packaging assembly processes. CCGA packages are used in space applications such as in logics and microprocessor functions, telecommunications, flight avionics, and payload electronics. As these packages tend to have less solder joint strain relief than leaded packages, the reliability of CCGA packages is very important for short- and long-term space missions. Certain planetary satellites require operations of thermally uncontrolled hardware under extremely cold and hot temperatures with large diurnal temperature change from day to night. The planetary protection requires the hardware to be baked at +125 C for 72 hours to kill microbugs to avoid any biological contamination, especially for sample return missions. Therefore, the present CCGA package reliability research study has encompassed the temperature range of 185 to +125 C to cover various NASA deep space missions. Advanced 1152 and 1272 CCGA packaging interconnects technology test hardware objects have been subjected to ex treme temperature thermal cycles from 185 to +125 C. X-ray inspections of CCGA packages have been made before thermal cycling. No anomalous behavior and process problems were observed in the x-ray images. The change in resistance of the daisy-chained CCGA interconnects was measured as a function of increasing number of thermal cycles. Electrical continuity measurements of daisy chains have shown no anomalies, even until 596 thermal cycles. Optical inspections of hardware have shown a significant fatigue for CCGA 1152 packages over CCGA 1272 packages. No catastrophic failures have been observed yet in the results. Process qualification and assembly are required to optimize the CCGA assembly processes. Optical inspections of CCGA boards have been made after 258 and 596 thermal cycles. Corner columns have started showing significant fatigue per optical inspection results.

Ramesham, Rajeshuni↗

SXI prototype mirror mount

The purpose of this contract was to provide optomechanical engineering and fabrication support to the Solar X-ray Imager (SXI) program in the areas of mirror, optical bench and camera assemblies of the telescope. The Center for Applied Optics (CAO) worked closely with the Optics and S&E technical staff of MSFC to develop and investigate the most viable and economical options for the design and fabrication of a number of parts for the various telescope assemblies. All the tasks under this delivery order have been successfully completed within budget and schedule. A number of development hardware parts have been designed and fabricated jointly by MSFC and UAH for the engineering model of SXI. The major parts include a nickel electroformed mirror and a mirror mount, plating and coating of the ceramic spacers, and gold plating of the contact rings and fingers for the camera assembly. An aluminum model of the high accuracy sun sensor (HASS) was also designed and fabricated. A number of fiber optic tapers for the camera assembly were also coated with indium tin oxide and phosphor for testing and evaluation by MSFC. A large number of the SXI optical bench parts were also redesigned and simplified for a prototype telescope. These parts include the forward and rear support flanges, front aperture plate, the graphite epoxy optical bench and a test fixture for the prototype telescope. More than fifty (50) drawings were generated for various components of the prototype telescope. Some of these parts were subsequently fabricated at UAH machine shop or at MSFC or by the outside contractors. UAH also provide technical support to MSFC staff for a number of preliminary and critical design reviews. These design reviews included PDR and CDR for the mirror assembly by United Technologies Optical Systems (UTOS), and the program quarterly reviews, and SXI PDR and CDR. UAH staff also regularly attended the monthly status reviews, and made a significant number of suggestions to improve the design, assembly and alignment of the telescope. Finally, a high level assembly and alignment plan for the entire telescope was prepared by UAH. This plan addresses the sequence of assembly, the required assembly and alignment tolerances, and the methods to verify the alignment at each step during the assembly process. This assembly and alignment plan will be used to assemble and integrate the engineering model (EM) of the telescope. Later on, based on this plan more detailed assembly and alignment procedures will be developed for the lower-level assemblies of SXI.

Source record↗

Towards Plume Impingement Modeling in Space Environments

After 30 years human presence in low-earth orbit, NASA is returning to the moon and eventually will go to Mars. To this end, NASA is constructing the Lunar Gateway, an ISS-like space station to act as a home base for Lunar exploration. A large space station must be assembled while in orbit, using a “piecemeal” approach. In this context, it means that the different modules will arrive at different times and attach to what is already in service. The ISS provides an excellent example of this approach, and the proposed Lunar Gateway will undergo a similar assembly process. This assembly is achieved via “docking” maneuvers between modules, which are made possible by sequential firings of the onboard reaction control system (RCS) thrusters. They work by firing hot gases to produce adverse thrust and the needed change in velocity to safely finish the docking approach. The issue is that the gas from these thrusters' forms flow structures described as “plumes” and can impinge onto the outer surfaces of the space station, causing unwanted forces and moments, heat loads, sediment deposition, and in extreme cases, even surface erosion. All mechanisms that can damage the space station and must be avoided. Both permanent and visiting modules will have these RCS thruster exhaust impingement problems. Accurately and efficiently modeling these plume is an involved multi-physics calculation but also an important tool when designing the control algorithms of approaching modules. This poster presents progress towards this simulation on two fronts. First is the verification of OpenFOAM for rarefied plume impingement calculations by direct comparison to published DAC cases. Second is the estimation of plume impingement strikes over the time scale of an entire docking event. This is done by using a simple plume source flow model and a prescribed motion visualizer—coded in Python. Together these tools help push NASA's capabilities for simulating these plume impingement effects.

Rarefied Flows↗

Lunar vehicle assembly and processing on Space Station Freedom

A concept is proposed that permits the accommodation of lunar vehicles on Space Station Freedom (SSF) within the context of the Human Exploration Initiative. The facility required for lunar-vehicle processing is defined with references to the types of support equipment assumed for these tasks. Attention is given to the SSF Assembly Complete, verification of the Lunar Transfer Vehicles (LTVs), and the attachments of reusable vs expendable LTVs. The impact of the assembly and processing operations is delineated with specific qualifications for revising the allowances for vehicle mass and controllability, reboost fuel needs, microgravity activities, and flight attitude. EVA working time is estimated for overhead and truss-assembly operations at about 3 months to support reusable LTV operations on the SSF. An Assembly/Servicing Facility is proposed for these activities with specific hardware options, and a hydrogen-oxygen propulsion system is proposed to make these activities more efficient.

Troutman, Patrick A.↗

Automated Multi-Robot Assembly of Compliance Optimized Structures

Autonomous assembly of large structures is one of the fundamental challenges on the way towards NASA’s objectives of deep space exploration. In this work, we propose an algorithmic framework to optimize the assembly process of a prescribed target structure by constraining the assembly effort as well as maintaining structural soundness throughout the process. This framework uses structural topology optimization with assembly effort metrics to generate checkpoints for robotic traversal algorithms. Assembly effort is quantified by the Wasserstein metric between consecutive structural configurations during the assembly process. The robotic assembly task is split into two subtasks, where we first optimize for a set of key frames, then perform reconfiguration between consecutive frames. Key frames are optimized by adopting topology optimization techniques to reduce assembly effort and maintain structural integrity during the assembly process, while reconfiguration between key frames is performed using a path planning algorithm with a minimum weight maximum matching approach on a bipartite graph. We employ a Crystalline robot model in which each structural element is capable of locomotion through the structure and locking into place with neighboring elements after reaching its destination. An example assembly of a two-dimensional cantilever beam under volume constraints and structural compliance considerations is presented to demonstrate the approach. Finally, we conclude by discussing possible future extensions to this work, including adoption of better metrics, extension to three-dimensional large-scale problems, and exacting finer control of structural integrity during the path-planning phase.

robotic assembly↗

Qualification of the gritblast assembly and process for the inside diameter of the RSRM forward and aft domes

This gritblast assembly shall be used when refurbishing the Inside Diameter (ID) of RSRM forward and aft domes. Initial blasting is used to remove corrosion and adhesive not removed during the insulation washout. Final blasting is conducted just prior to part finalization in order to remove residual contamination and prepare the ID surface for bonding. The media used in this gritblaster is DuPont Zirclean Blasting Abrasive. It is possible to use other media in this gritblast assembly, however the only facility that has the control capability for this assembly is the Zirclean blast booth. This blast booth can not use other media without the occurrence of contamination. This automated process shall replace the manually controlled gritblasting that is currently in operation. Manual gritblasting does not provide the consistency, control, and safety that an automated process is capable of delivering.

Nolan, Michael J.↗

(abstract) Designing for Small Volume Assembly of Advanced Electronics Packages

There is a need for high reliability surface mount assembly processes for aerospace, military, and medical applications. This approach for improving design for producibility and reliability of electronic system assembly processes can be utilized as a starting framework. Described herein is a general methodology to Design for Producibility and Reliability (DFPAR) for very small volume production runs.

assembly processes↗