JPL standard for spacecraft system dynamic and static testing
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dynamic static testing spacecraft testing↗
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Development of structural dynamic test environments for subsystems and components
Structural dynamic environmental test levels were developed for the thematic mapper instrument, components of the Tandberg-Hanssen instrument, and components of the International Ultraviolet Explorer spacecraft using NASTRAN structural models and test data. Both static and dynamic NASTRAN analyses were used. The model size required could be as small as 300 degrees of freedom for the static analysis and as large as 4000 degrees of freedom or more for the high frequency dynamic analysis. An important step in the development of the levels is model verification by test. The launch environments that generally dictate many important features of the design of an instrument or component are steady state acceleration, sinusoidal vibration, and random vibration.
Coladonato, R. J.↗
Vibration and acoustic testing of spacecraft
Spacecraft are subjected to a variety of dynamics environments, which may include: quasi-static, vibration and acoustic loads at launch: pyrotechnic shocks generated by separation mechanisms; on orbit jitter; and sometimes, planetary landing loads. There is a trend in the aerospace industry to rely more on structural analyses and less on testing to simulate these environments, because dynamics testing of spacecraft is time consuming, risky and expensive.
vibration acoustics spacecraft↗
Dynamic testing techniques for qualifying Mars Eploration Rover equipment to quasi-static landing loads
In mid 2003, NASA will launch identical spacecraft to deliver two large rovers to the Martian surface. As with the successful Mars Pathfinder (MPF) mission, the MER spacecraft will use an airbag landing system to safely deliver its payload.
quasi-static loads limit load static testing elect↗
25th Space Simulation Conference. Environmental Testing: The Earth-Space Connection
Topics covered include: Methods of Helium Injection and Removal for Heat Transfer Augmentation; The ESA Large Space Simulator Mechanical Ground Support Equipment for Spacecraft Testing; Temperature Stability and Control Requirements for Thermal Vacuum/Thermal Balance Testing of the Aquarius Radiometer; The Liquid Nitrogen System for Chamber A: A Change from Original Forced Flow Design to a Natural Flow (Thermo Siphon) System; Return to Mercury: A Comparison of Solar Simulation and Flight Data for the MESSENGER Spacecraft; Floating Pressure Conversion and Equipment Upgrades of Two 3.5kw, 20k, Helium Refrigerators; Affect of Air Leakage into a Thermal-Vacuum Chamber on Helium Refrigeration Heat Load; Special ISO Class 6 Cleanroom for the Lunar Reconnaissance Orbiter (LRO) Project; A State-of-the-Art Contamination Effects Research and Test Facility Martian Dust Simulator; Cleanroom Design Practices and Their Influence on Particle Counts; Extra Terrestrial Environmental Chamber Design; Contamination Sources Effects Analysis (CSEA) - A Tool to Balance Cost/Schedule While Managing Facility Availability; SES and Acoustics at GSFC; HST Super Lightweight Interchangeable Carrier (SLIC) Static Test; Virtual Shaker Testing: Simulation Technology Improves Vibration Test Performance; Estimating Shock Spectra: Extensions beyond GEVS; Structural Dynamic Analysis of a Spacecraft Multi-DOF Shaker Table; Direct Field Acoustic Testing; Manufacture of Cryoshroud Surfaces for Space Simulation Chambers; The New LOTIS Test Facility; Thermal Vacuum Control Systems Options for Test Facilities; Extremely High Vacuum Chamber for Low Outgassing Processing at NASA Goddard; Precision Cleaning - Path to Premier; The New Anechoic Shielded Chambers Designed for Space and Commercial Applications at LIT; Extraction of Thermal Performance Values from Samples in the Lunar Dust Adhesion Bell Jar; Thermal (Silicon Diode) Data Acquisition System; Aquarius's Instrument Science Data System (ISDS) Automated to Acquire, Process, Trend Data and Produce Radiometric System Assessment Reports; Exhaustive Thresholds and Resistance Checkpoints; Reconfigurable HIL Testing of Earth Satellites; FPGA Control System for the Automated Test of MicroShutters; Ongoing Capabilities and Developments of Re-Entry Plasma Ground Tests at EADS-ASTRIUM; Operationally Responsive Space Standard Bus Battery Thermal Balance Testing and Heat Dissipation Analysis; Galileo - The Serial-Production AIT Challenge; The Space Systems Environmental Test Facility Database (SSETFD), Website Development Status; Simulated Reentry Heating by Torching; Micro-Vibration Measurements on Thermally Loaded Multi-Layer Insulation Samples in Vacuum; High Temperature Life Testing of 80Ni-20Cr Wire in a Simulated Mars Atmosphere for the Sample Analysis at Mars (SAM) Instrument Suit Gas Processing System (GPS) Carbon Dioxide Scrubber; The Planning and Implementation of Test Facility Improvements; and Development of a Silicon Carbide Molecular Beam Nozzle for Simulation Planetary Flybys and Low-Earth Orbit.
Packard, Edward↗
The effect of nonlinearities on the dynamic response of a large shuttle payload
The STS Centaur was designed to be a high energy upper stage for use with the Space Shuttle. Two versions were designed under development when the program was cancelled. The first version, designated G-prime, was for planetary missions. The second version, designated G, was to place spacecraft in geosynchronous orbit. As a part of the STS Centaur finite-element model verification effort, test articles of both versions were subjected to a series of static tests. In addition the Centaur G-prime test article was subjected to a series of dynamic tests including a modal survey. Both the static and dynamic tests showed that nonlinearities existed in the Centaur and its support system. The support system included flight-like latches. The nonlinearities were particularly apparent in tests that loaded the forward support structure of the Centaur. These test results were used to aid in the development of two improved finite-element models. The first was a linear model, while the second contained nonlinear elements at the boundaries. Results from both models were compared with the transient response obtained from a step-relaxation or twang test. The linear model was able to accurately match the low frequency response found in the test data. However, only the nonlinear model was able to match higher frequency response that was present in some of the test data. In addition the nonlinear model was able to predict other nonlinear behavior such as the dynamic jump that occurs in systems with nonlinear stiffness.
Sullivan, Timothy L.↗
Piezoelectric Bolt Breakers and Bolt Fatigue Testers
A proposed family of devices for inducing fatigue in bolts in order to break the bolts would incorporate piezoelectric actuators into resonant fixtures as in ultrasonic/ sonic drills/corers and similar devices described in numerous prior NASA Tech Briefs articles. These devices were originally intended primarily for use as safer, more-reliable, more-versatile alternatives to explosive bolts heretofore used to fasten spacecraft structures that must subsequently be separated from each other quickly on command during flight. On Earth, these devices could be used for accelerated fatigue testing of bolts. Fatigue theory suggests that a bolt subjected to both a constant-amplitude dynamic (that is, oscillatory) stress and a static tensile stress below the ultimate strength of the bolt material will fail faster than will a bolt subjected to only the dynamic stress. This suggestion would be applied in a device of the proposed type. The device would be designed so that the device and the bolt to be fatigue-tested or broken would be integral parts of an assembly (see figure). The static tension in the tightened bolt would apply not only the clamping force to hold the joined structures (if any) together but also the compression necessary for proper operation of the piezoelectric actuators as parts of a resonant structural assembly. The constant-amplitude dynamic stress would be applied to the bolt by driving the piezoelectric actuators with a sinusoidal voltage at the resonance frequency of longitudinal vibration of the assembly. The amplitude of the excitation would be made large enough so that the vibration would induce fatigue in the bolt within an acceptably short time. In the spacecraft applications or in similar terrestrial structural-separation applications, devices of the proposed type would offer several advantages over explosive bolts: Unlike explosive bolts, the proposed devices would be reusable, could be tested before final use, and would not be subject to catastrophic misfire. In fatigue-testing applications, devices of the proposed type would offer advantages of compactness and low cost, relative to conventional fatigue- testing apparatuses. In both structural- separation and fatigue-testing applications, bolts to be broken or tested could be instrumented with additional ultrasonic transducers for monitoring of pertinent physical properties and of fatigue failure processes.
Sherrit, Stewart↗
The effect of nonlinearities on the dynamic response of a large Shuttle payload
The STS Centaur was designed to be a high energy upper stage for use with the Space Shuttle. Two versions were designed and under development when the program was cancelled. The first version, designated G-prime, was designed for planetary missions. The second version, designated G, was designed to place spacecraft in geosynchronous orbit. As a part of the STS Centaur finite-element model verification effort, test articles of both versions were subjected to a series of static tests. In addition the Centaur G-prime test article was subjected to a series of dynamic tests including a modal survey. Both the static and dynamic tests showed that nonlinearities existed in the Centaur and its support system. The support system included flight-like latches. The nonlinearities were particularly apparent in tests that loaded the forward support structure of the Centaur. These test results were used to aid in the development of two improved finite-element models. The first was a linear model, while the second contained nonlinear elements at the boundaries. Results from both models were compared with the transient response obtained from a step-relaxation or twang test. The linear model was able to accurately match the low frequency response found in the test data. However, only the nonlinear model was able to match higher frequency response that was present in some of the test data. In addition the nonlinear model was able to predict other nonlinear behavior such as the dynamic 'jump' that occurs in systems with nonlinear stiffness.
Sullivan, Timothy L.↗
NASTRAN: Users' experiences
The proceedings of a conference on NASA Structural Analysis (NASTRAN) to analyze the experiences of users of the program are presented. The subjects discussed include the following: (1) statics and buckling, (2) vibrations and dynamics, (3) substructing, (4) new capability, (5) user's experience, and (6) system experience. Specific applications of NASTRAN to spacecraft, aircraft, nuclear power plants, and materials tests are reported.
Source record↗
Galileo spacecraft modal test and evaluation of testing techniques
The structural configuration, modal test requirements and pre-test activities involved in modeling the expected dynamic environment and responses of the Galileo spacecraft are discussed. The probe will be Shuttle-launched in 1986 and will gather data on the Jupiter system. Loads analysis for the 5300 lb spacecraft were performed with the NASTRAN code, and covered 10,000 static degrees of freedom and 1600 mass degrees of freedom. A modal analysis will be used to verify the predictions for natural frequencies, mode shapes, orthogonality checks, residual mass, modal damping and forces, and generalized forces. Verification of the validity of considering only 70 natural modes in the numerical simulation is being performed by examining the forcing functions of the analysis. The analysis led to requirements that 162 channels of accelerometer data and 118 channels of strain gage data be recorded during shaker tests to reveal areas where design changes will be needed to eliminate vibration peaks.
Chen, J.-C.↗
A method for the measurement of extremely feeble torques on massive bodies.
Single-axis meter design and development for measuring feeble torques on massive bodies, discussing calibration, testing results, evaluation of static dipole moments and spacecraft spin-rate control moments
SPACECRAFT PERFORMANCE↗
A comparison of controller designs for an experimental flexible structure
Control systems design and hardware testing are addressed for an experimental structure that displays the characteristics of a typical flexible spacecraft. The results of designing and implementing various control design methodologies are described. The design methodologies under investigation include linear quadratic Gaussian control, static and dynamic dissipative controls, and H-infinity optimal control. Among the three controllers considered, it is shown, through computer simulation and laboratory experiments on the evolutionary structure, that the dynamic dissipative controller gave the best results in terms of vibration suppression and robustness with respect to modeling errors.
Lim, K. B.↗
Test Verification of the Cassini Spacecraft Dynamic Model
The Cassini spacecraft mission to Saturn will be launched in October 1997, on a Titan IV/Centaur launch vehicle. Cassini is the largest interplanetary spacecraft ever developed. Before launch approval can be obtained, a test verified finite element model of the Cassini spacecraft must be completed and approved by NASA. The correctness of this model is critical to the final verification coupled loads analysis and margin of safety assessments.
Cassini↗
ERBE - Assessment of measurement accuracy
The Earth Radiation Budget Experiment (ERBE) represents a continuing effort to estimate the solar incident and earth reflected and emitted radiance from spacecraft measurements. The development of accurate and stable sensors and calibration sources is mandatory but not sufficient to attain and validate required measurement accuracies. It is also necessary to develop and experimentally test computational models of the calibration and measurement processes to account for environmental differences between (static) calibrations and (dynamic) measurements of the earth radiant exitance that varies with wavelength, position, direction, and time.
Spiers, R. B., Jr.↗
Special tooling for joining tubing in place
The Saturn S-II stage and the Apollo spacecraft will include in their design and construction various pressurized tubing systems that will encounter service temperatures of 280° F to -423° F. Design engineering and reliability requirements and weight restrict ions have dictated new concepts to assure leak-tight joints for rocket engine fuel lines, pressurization systems, utility systems, and hydraulic systems. An investigation was initiated at North American Aviation, Inc., Space and Information Systems Division, utilizing the in-place automatically controlled miniaturized fusion-welding equipment originally developed by the Los Angeles Division of NAA and modified to meet the needs of Apollo and Saturn welded tubular systems. The objective was to make circumferential flanged weld joints in any position in 304L stainless for Saturn S-II and sleeve-type joints in 304L for Apollo. Inconel X, commercially pure titanium, 5052-0 aluminum, and 6061 T6 aluminum were also tested experimentally. Extensive environmental, static, and dynamic testing programs were conducted to determine the as-welded mechanical properties, design allowables, and reliability for the tube joints. This paper discusses both the experimental and production phases. Subsequently, the new tube welding process was approved and incorporated into manufacturing fabrication methods for tube joining.
Saturn S-II stage↗
Drag-Free Control and Drag Force Recovery of Small Satellites
Drag-free satellites provide autonomous precision orbit determination, accurately map the static and time varying components of Earth's mass distribution, aid in our understanding of the fundamental force of gravity, and will ultimately open up a new window to our universe through the detection and observation of gravitational waves. At the heart of this technology is a gravitational reference sensor, which (a) contains and shields a free-floating proof mass from all non-gravitational forces, and (b) precisely measures the position of the test mass inside the sensor. Thus, both test mass and spacecraft follow a pure geodesic in spacetime. By tracking the position of a low Earth orbiting drag-free satellite we can directly determine the detailed shape of geodesics and through analysis, the higher order harmonics of the Earths geopotential. This paper explores two different drag-free control systems on small satellites. The first drag-free control system is a continuously compensated single thruster 3-unit CubeSat with a suspension-free spherical proof-mass. A feedback control system commands the thruster and Attitude and Determination Control System to fly the tender spacecraft with respect to the test mass. The spheres position is sensed with a LED-based differential optical shadow sensor, its electric charge controlled by photoemission using UV LEDs, and the spacecraft position is maintained with respect to the sphere using an ion electrospray propulsion system. This configuration is the most fuel-efficient drag-free system possible today. The second drag-free control system is an electro-statically suspended cubical proof-mass that is operated with a low duty cycle, limiting suspension force noise over brief, known time intervals on a small GRACE-II -like satellite. The readout is performed using a laser interferometer, which is immune to the dynamic range limitations of voltage references. This system eliminates the need for a thruster, enabling drag-free control systems for passive satellites. In both cases, the test mass position, GPS tracking data, and commanded actuation, either thrust or suspension system, can be analyzed to estimate the 3-axis drag forces acting on the satellite. The data produces the most precise maps of upper atmospheric drag forces and with additional information, detailed models that describe the dynamics of the upper atmosphere and its impact on all satellites that orbit the Earth. This paper highlights the history, applications, design, laboratory technology development and highly detailed simulation results of each control system.
Small Satellites↗
Application of the Two-Step Filter to Process Ranging Measurements for Relative Navigation in an Elliptical Orbit
This estimator breaks a nonlinear estimation problem into a set of over determined 'first step' states which are linear in the observations and 'second step' states which are ultimately the states of interest. Linear estimation methods are applied to filter the observations and produce the optimal first step state estimate. The 'second step' states are obtained through iterative nonlinear parameter estimation considering the first step states as observations. It has been shown that this process exactly minimizes the least squares cost function for static problems and provides a better solution than the iterated extended Kalman filter (EKF) for dynamic problems. The two step filter is applied in this paper to process range and range rate measurements between the two spacecraft. Details of the application of the two step estimator to this problem will be given, highlighting the use of a test for ill-conditioned covariance estimates that can result from the first order covariance propagation. A comparison will be made between the performance of the two step filter and the IEKF.
Garrison, James L.↗
Engineering America's Current and Future Space Transportation Systems: 50 Years of Systems Engineering Innovation for Sustainable Exploration
Over the past 50 years, the National Aeronautics and Space Administration (NASA) has delivered space transportation solutions for America's complex missions, ranging from scientific payloads that expand knowledge, such as the Hubble Space Telescope, to astronauts and lunar rovers destined for voyages to the Moon. Currently, the venerable Space Shuttle, which has been in service since 1981, provides the United States' (U.S.) capability for both crew and heavy cargo to low-Earth orbit to' construct the International Space Station, before the Shuttle is retired in 2010. In the next decade, NASA will replace this system with a duo of launch vehicles: the Ares I Crew Launch Vehicle and the Ares V Cargo Launch Vehicle (Figure 1). The goals for this new system include increased safety and reliability coupled with lower operations costs that promote sustainable space exploration for decades to come. The Ares I will loft the Orion Crew Exploration Vehicle, while the heavy-lift Ares V will carry the Altair Lunar Lander and the equipment and supplies needed to construct a lunar outpost for a new generation of human and robotic space pioneers. This paper will provide details of the in-house systems engineering and vehicle integration work now being performed for the Ares I and planned for the Ares V. It will give an overview of the Ares I system-level test activities, such as the ground vibration testing that will be conducted in the Marshall Center's Dynamic Test Stand to verify the integrated vehicle stack's structural integrity and to validate computer modeling and simulation (Figure 2), as well as the main propulsion test article analysis to be conducted in the Static Test Stand. These activities also will help prove and refine mission concepts of operation, while supporting the spectrum of design and development work being performed by Marshall's Engineering Directorate, ranging from launch vehicles and lunar rovers to scientific spacecraft and associated experiments. Ultimately, fielding a robust space transportation solution that will carry international explorers and essential payloads will pave the way for a new century of scientific discovery beyond planet Earth.
Dmbacher, Daniel L.↗