CM and drawing release in a rapid prototyping environment
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Decal Process Document and Catalog
The Decal Process Document and Catalog, JSC 27260 is the standard flight decal catalog, complete with illustrations and part numbers. As hardware developers identify labels that have common applicability across end items, these labels can be evaluated for "standard decal classification" and entered into the decal catalog for general use. The hardware developer must have a label design that meets current, applicable labeling requirements, and submit to the Decal Design and Production Facility (DDPF) as a standard label candidate. Upon approval, the label will be added to the decal catalog. The Decal Process Document and Catalog provides a selection of decals from which the NASA and NASA contractor customers can easily order. The decals shown in the catalog have been previously produced and have released engineering/fabrication drawings on file in the (DDPF). A released drawing is required before a decal can be produced or placed into the catalog. Some decals included in the catalog have a common applicability and are used in various NASA vehicles/habitats. It is the intent of the DDPF to maintain this catalog as a "living document" to which decals/placards can be added as they are repeatedly used. The advantage of identifYing flight decals in this catalog is that a released drawing is already in place, and the products will be flight certified.
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Space shuttle main engine controller assembly, phase C-D
System design and system analysis and simulation are slightly behind schedule, while design verification testing has improved. Input/output circuit design has improved, but digital computer unit (DCU) and mechanical design continue to lag. Part procurement was impacted by delays in printed circuit board, assembly drawing releases. These are the result of problems in generating suitable printed circuit artwork for the very complex and high density multilayer boards.
Source record↗
Architectural, Mechanical, Electrical, Plumbing, and Site Documents Associated with Sustainability Base, N232
These files contain more precise and accurate representations of the architectural, mechanical, electrical, plumbing, and site information pertaining to Sustainability Base, aka Collaborative Support Facility, aka N232. These supersede the 'bid' drawings released in STI 8112 previously. They are useful for NASA researchers and collaborators in modeling the performance characteristics of the facility. Otherwise, they do not contain new data.
Buildings↗
Theory Validation - 2 Points of View
The task of validating any given theory against any given proprotor/propeller data set is of immense importance. Not just to the researchers who are developing a theory, but to the working engineers using the theory to design a proprotor/propeller. However, there is major difference in how the two groups see validation. This difference is that, most frequently, researchers see the validation in coefficient form as, for example, CP versus CT or Figure of Merit versus CT. In contrast, design engineers are always working in the dimensional world as, for example, horsepower required to hover versus aircraft weight. The objective of the design engineer is, of course, to release drawings and specifications to manufacturing so a VTOL aircraft will be built with reasonably high assurance that the aircraft will meet the primary specifications.
Harris, Franklin D.↗
Development and fabrication of a solar cell junction processing system
The major component fabrication program was completed. Assembly and system testing of the pulsed electron beam annealing machine are described. The design program for the transport reached completion, and the detailed drawings were released for fabrication and procurement of the long lead time components.
Kiesling, R.↗
Development and fabrication of a solar cell junction processing system
Modifications to the ground plane, to insure a good electrical return path during the pulse discharge, were made using a ring of beryllium copper finger stock attached to the underside of the aluminum ground plate. Experiments on annealing of wafers with ion implantation damage continued. The entire surface of 100 mm diameter wafers were annealed by one pulse for the standard implant (10 keV, phosphorus, 2x10 to the 15th power ions/sq cm). While samples are being fabricated into solar cells for electrical characterization, work is continuing on improvement of the electron beam uniformity and the optimization of the diode parameters. The engineering design was completed and the manufacturing detail drawings were released for fabrication. Assembly of the subcomponents for the exit and entrance locks is almost complete. These components include the cassettes, the indexing mechanisms, main doors, and wafer carrier transfer modules. The 'Y' track and three phase transition track sections are under final assembly and test.
Giesling, R.↗
X-33/RLV Program Aerospike Engines
Substantial progress was made during the past year in support of the X-33/RLV program. X-33 activity was directed towards completing the remaining design work and building hardware to support test activities. RLV work focused on the nozzle ramp and powerpack technology tasks and on supporting vehicle configuration studies. On X-33, the design activity was completed to the detail level and the remainder of the drawings were released. Component fabrication and engine assembly activity was initiated, and the first two powerpacks and the GSE and STE needed to support powerpack testing were completed. Components fabrication is on track to support the first engine assembly schedule. Testing activity included powerpack testing and component development tests consisting of thrust cell single cell testing, CWI system spider testing, and EMA valve flow and vibration testing. Work performed for RLV was divided between engine system and technology development tasks. Engine system activity focused on developing the engine system configuration and supporting vehicle configuration studies. Also, engine requirements were developed, and engine performance analyses were conducted. In addition, processes were developed for implementing reliability, mass properties, and cost controls during design. Technology development efforts were divided between powerpack and nozzle ramp technology tasks. Powerpack technology activities were directed towards the development of a prototype powerpack and a ceramic turbine technology demonstrator (CTTD) test article which will allow testing of ceramic turbines and a close-coupled gas generator design. Nozzle technology efforts were focused on the selection of a composite nozzle supplier and on the fabrication and test of composite nozzle coupons.
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Testing for the J-2X Upper Stage Engine
NASA selected the J-2X Upper Stage Engine in 2006 to power the upper stages of the Ares I crew launch vehicle and the Ares V cargo launch vehicle. Based on the proven Saturn J-2 engine, this new engine will provide 294,000 pounds of thrust and a specific impulse of 448 seconds, making it the most efficient gas generator cycle engine in history. The engine's guiding philosophy emerged from the Exploration Systems Architecture Study (ESAS) in 2005. Goals established then called for vehicles and components based, where feasible, on proven hardware from the Space Shuttle, commercial, and other programs, to perform the mission and provide an order of magnitude greater safety. Since that time, the team has made unprecedented progress. Ahead of the other elements of the Constellation Program architecture, the team has progressed through System Requirements Review (SRR), System Design Review (SDR), Preliminary Design Review (PDR), and Critical Design Review (CDR). As of February 2010, more than 100,000 development engine parts have been ordered and more than 18,000 delivered. Approximately 1,300 of more than 1,600 engine drawings were released for manufacturing. A major factor in the J-2X development approach to this point is testing operations of heritage J-2 engine hardware and new J-2X components to understand heritage performance, validate computer modeling of development components, mitigate risk early in development, and inform design trades. This testing has been performed both by NASA and its J-2X prime contractor, Pratt & Whitney Rocketdyne (PWR). This body of work increases the likelihood of success as the team prepares for testing the J-2X powerpack and first development engine in calendar 2011. This paper will provide highlights of J-2X testing operations, engine test facilities, development hardware, and plans.
Buzzell, James C.↗
Universal Pouch Cell Test Fixtures
To release information to United States Navy, Naval Research Laboratory. Information to be released includes drawings of universal cell test fixtures developed at Idaho National Laboratory.
25 ENERGY STORAGE↗
Fuel element debris pic tool
We would like to release 2 drawings to NIST/NCNR reactor to assist in fuel element cleaning
11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
Design Process of Flight Vehicle Structures for a Common Bulkhead and an MPCV Spacecraft Adapter
Design and manufacturing space flight vehicle structures is a skillset that has grown considerably at NASA during that last several years. Beginning with the Ares program and followed by the Space Launch System (SLS); in‐house designs were produced for both the Upper Stage and the SLS Multipurpose crew vehicle (MPCV) spacecraft adapter. Specifically, critical design review (CDR) level analysis and flight production drawing were produced for the above mentioned hardware. In particular, the experience of this in‐house design work led to increased manufacturing infrastructure for both Marshal Space Flight Center (MSFC) and Michoud Assembly Facility (MAF), improved skillsets in both analysis and design, and hands on experience in building and testing (MSA) full scale hardware. The hardware design and development processes from initiation to CDR and finally flight; resulted in many challenges and experiences that produced valuable lessons. This paper builds on these experiences of NASA in recent years on designing and fabricating flight hardware and examines the design/development processes used, as well as the challenges and lessons learned, i.e. from the initial design, loads estimation and mass constraints to structural optimization/affordability to release of production drawing to hardware manufacturing. While there are many documented design processes which a design engineer can follow, these unique experiences can offer insight into designing hardware in current program environments and present solutions to many of the challenges experienced by the engineering team.
Aggarwal, Pravin↗
Electrodynamic Tether
A tether system for providing thrust to or power subsystems of an artificial satellite in a low earth orbit. The tether has three main sections, an insulated section connected to the satellite, a conducting section connected to the insulating section for drawing in and releasing electrons from the space plasma and a non-conducting section for providing a tension to the other sections of the tether. An oxygen resistant coating is applied to the bare wire of the conducting section as well as the insulated wires of the insulated section that prevents breakdown during tether operations in the space plasma. The insulated and bare wire sections also surround a high tensile flexible polymer core to prevent any debris from breaking the tether during use.
Johnson, Charles L.↗
From Paper to Production: An Update on NASA's Upper Stage Engine for Exploration
In 2006, NASA selected an evolved variant of the proven Saturn/Apollo J-2 upper stage engine to power the Ares I crew launch vehicle upper stage and the Ares V cargo launch vehicle Earth departure stage (EDS) for the Constellation Program. Any design changes needed by the new engine would be based where possible on proven hardware from the Space Shuttle, commercial launchers, and other programs. In addition to the thrust and efficiency requirements needed for the Constellation reference missions, it would be an order of magnitude safer than past engines. It required the J-2X government/industry team to develop the highest performance engine of its type in history and develop it for use in two vehicles for two different missions. In the attempt to achieve these goals in the past five years, the Upper Stage Engine team has made significant progress, successfully passing System Requirements Review (SRR), System Design Review (SDR), Preliminary Design Review (PDR), and Critical Design Review (CDR). As of spring 2010, more than 100,000 experimental and development engine parts have been completed or are in various stages of manufacture. Approximately 1,300 of more than 1,600 engine drawings have been released for manufacturing. This progress has been due to a combination of factors: the heritage hardware starting point, advanced computer analysis, and early heritage and development component testing to understand performance, validate computer modeling, and inform design trades. This work will increase the odds of success as engine team prepares for powerpack and development engine hot fire testing in calendar 2011. This paper will provide an overview of the engine development program and progress to date.
Kynard, Mike↗
Storing Fluorine In Graphitelike Carbon Fibers
Fluorine stored in graphite or graphitelike carbon fibers for later release and/or use in chemical reactions. Storage in carbon fibers eliminates difficulty and risk of using high-pressure tanks and pipes to hold corrosive gas. Storage in carbon fibers makes fluorine more readily accessible than does storage as constituent of metal fluoride. Carbon fibers heated to release stored fluorine, which draws away to vessel where reacts with material to be fluorinated, possibly at temperature other than release temperature. Alternatively, material to be fluorinated mixed or otherwise placed in contact with fibers and entire mass heated to or beyond release temperature.
Hung, Ching-Cheh↗
Mail LOG: Program operating instructions
The operating instructions for the software package, MAIL LOG, developed for the Scout Project Automatic Data System, SPADS, are provided. The program is written in FORTRAN for the PRIME 300 computer system. The MAIL LOG program has the following four modes of operation: (1) INPUT - putting new records into the data base (2) REVISE - changing or modifying existing records in the data base (3) SEARCH - finding special records existing in the data base (4) ARCHIVE - store or put away existing records in the data base. The output includes special printouts of records in the data base and results from the INPUT and SEARCH modes. The MAIL LOG data base consists of three main subfiles: Incoming and outgoing mail correspondence; Design Information Releases and Releases and Reports; and Drawings and Engineering orders.
Harris, D. K.↗
MAIL LOG, program theory, volume 1
The program theory used to obtain the software package, MAIL LOG, developed for the Scout Project Automatic Data System, SPADS, is described. The program is written in FORTRAN for the PRIME 300 computer system. The MAIL LOG data base consists of three main subfiles: (1) incoming and outgoing mail correspondence; (2) design information releases and reports; and (3) drawings and engineering orders. All subroutine descriptions, flowcharts, and MAIL LOG outputs are given and the data base design is described.
Harris, D. K.↗
Reference Management Methodologies for Large Structural Models at Kennedy Space Center
There have been many challenges associated with modeling some of NASA KSC's largest structures. Given the size of the welded structures here at KSC, it was critically important to properly organize model struc.ture and carefully manage references. Additionally, because of the amount of hardware to be installed on these structures, it was very important to have a means to coordinate between different design teams and organizations, check for interferences, produce consistent drawings, and allow for simple release processes. Facing these challenges, the modeling team developed a unique reference management methodology and model fidelity methodology. This presentation will describe the techniques and methodologies that were developed for these projects. The attendees will learn about KSC's reference management and model fidelity methodologies for large structures. The attendees will understand the goals of these methodologies. The attendees will appreciate the advantages of developing a reference management methodology.
Jones, Corey↗