Research and Technology 1998 Annual Report - Kennedy Space ...

NASA Technical Memorandum 208545Research and Technology1998 Annual ReportJohn F. Kennedy Space Center

About the CoverThe three technology links to access space are the Launch and LaunchVehicle Processing Systems, the Payload and Payload Carrier ProcessingSystems, and the Landing and Recovery Systems. These technology linkssupport KSC’s Strategic Roadmap to the Future. The center illustrationdepicts KSC as the future Spaceport Technology Center.Cover art: by Caroline ZafferyDynacs Engineering Co., Inc.Engineering Development Contract

NASA Research Technical Memorandum Technology 208545 1998Research and Technology1998 Annual ReportJohn F. Kennedy Space Centeri

Research and Technology 1998ForewordAs the NASA Center responsible for preparingand launching space missions, theJohn F. Kennedy Space Center (KSC) isplacing increasing emphasis on its advancedtechnology development program.KSC is transitioning from an operations toa spaceport technology developmentcenter. Our technology developmentencompasses the efforts of the entire KSCteam, consisting of Government and contractorpersonnel, working in partnershipwith academic institutions and commercialindustry. This edition of the KSC Researchand Technology 1998 Annual Report covers the efforts of these contributorsto the KSC advanced technology development program, as well as our technologytransfer activities.Gale Allen, Associate Director of KSC’s Technology Programs and Commercializationorganization, (407) 867-6226, is responsible for publication of thisreport and should be contacted for any desired information regarding theadvanced technology program.Roy D. Bridges, Jr.Directori/ii iii

Research and Technology 1998CONTENTSLIFE SCIENCES ................................................................................................................................................................................. 1Candidate Crop Evaluation for Advanced Life Support and Gravitational Biology and Ecology................................................... 2Plant Nutrient Delivery Systems .................................................................................................................................................... 4Plant Lighting Systems ....................................................................................................................................................................... 5Microbial Ecology of Bioregenerative Life Support Systems for Space Exploration.......................................................................... 6MECHANICAL ENGINEERING ..................................................................................................................................................... 9Insulation Testing Using a Cryostat Apparatus With Sleeve......................................................................................................... 10Development of a Multipurpose Cryostat for Insulation Testing ................................................................................................... 12Cryogenics Test Laboratory ............................................................................................................................................................. 13Verification Test Article Project ...................................................................................................................................................... 14Liquid Nitrogen Feed System and Subcooler for the Cryostat ........................................................................................................ 16Liquid Nitrogen Flow Test Area ...................................................................................................................................................... 17Analysis of Nonstationary Signals Using Wavelets for Extracting Resonances ........................................................................... 18ENVIRONMENTAL ENGINEERING .......................................................................................................................................... 21Habitat Management and Ecological Risk Assessment Modeling ................................................................................................. 22Threatened and Endangered Species Monitoring ........................................................................................................................... 24Pilot-Scale Evaluation of a New Technology To Control NOx Emissions From Stationary Combustion Sources ......................... 26Development of an In Situ Technique for Electrokinetic Remediation of Soils Contaminated With Heavy Metals ...................... 28Enhanced In Situ Zero-Valent Metal Permeable Treatment Walls ................................................................................................. 30Installation of a New Scrubber Liquor for the Nitrogen Tetroxide Scrubbers That Produces a Commercial Fertilizer ................. 32Less Toxic Orbiter TPS Rewaterproofing Agent Study .................................................................................................................. 34Supercritical Air-Powered Environmental Control Unit for SCAPE ............................................................................................ 36ADVANCED SOFTWARE ............................................................................................................................................................... 37Mars ISPP Autonomous Controller ................................................................................................................................................ 38JView Internet Display of Shuttle Real-Time Data Using Java ....................................................................................................... 40Automation of OMI S9002 for Orbiter Processing ......................................................................................................................... 42Web-Based Work Tracking Systems ................................................................................................................................................. 44ATMOSPHERIC SCIENCE ............................................................................................................................................................. 47Hurricane Wind Sensor ................................................................................................................................................................... 48Single-Station Accurate Location of Lightning Strikes ................................................................................................................... 50viii

ContentsCONTENTS (cont)MATERIALS SCIENCE ................................................................................................................................................................... 53Study of Electrostatic Charging and Discharging of Materials in a Simulated Martian Environment .......................................... 54Investigation of Water Soluble Polyaniline as a Replacement for Chromate Coatings on Aluminum Alloys ................................ 56Qualified Materials Listings for Plastic Films and Adhesive Tapes ................................................................................................. 57Determination of Sodium in Colloidal Silica .................................................................................................................................... 58Radiant Heating Facility ................................................................................................................................................................... 60X-33 Rocket System Fuel Tank Electrostatic Coating ..................................................................................................................... 61Analysis of Chloropel by Direct Pyrolysis/FTIR ............................................................................................................................. 62Hydrolytic Degradation of Polyimide Wire Insulation .................................................................................................................... 64Epoxy Bonding Agents .................................................................................................................................................................. 66Cryogenic Insulation Systems for Soft Vacuum .............................................................................................................................. 68Permanent Antistatic SCAPE Suit Coating.................................................................................................................................... 70NONDESTRUCTIVE EVALUATION .......................................................................................................................................... 71Condition Monitoring and Fault Identification in Rotating Machinery (CONFIRM) .................................................................... 72Evolved Expendable Launch Vehicle (EELV) Hydrogen Testing ....................................................................................................... 74Thermography for Nondestructive Evaluation and Laser Shearography .......................................................................................... 76PROCESS/INDUSTRIAL ENGINEERING .............................................................................................................................. 77Management Support Systems: Goal Performance Evaluation System ....................................................................................... 78Management Support Systems: Organizational Change Models for Strategic Management ..................................................... 80Management Support Systems: Methodology To Harvest Intellectual Property at KSC ............................................................ 82Management Support Systems: KSC Customer Focus Process Development ............................................................................... 84Management Support Systems: Balanced Scorecard Metrics ......................................................................................................... 86Management Support Systems: Program Corporate Memory — a Knowledge Repository for KSC ........................................... 88Human Factors Engineering: Root-Cause Analysis System .......................................................................................................... 90Human Factors Engineering: Applications in the Checkout and Launch Control System ............................................................ 92Human Factors Engineering: Human Error Research in Shuttle Processing and Aircraft Maintenance Operations .................. 94Work Methods and Measurement: Expert System To Generate Job Standards .............................................................................. 96Work Methods and Measurement: Electronic Portable Information Collection .............................................................................. 98Work Methods and Measurement: Work Instruction Task Team ................................................................................................. 100Work Methods and Measurement: Industrial Engineering Decision Support Tool ..................................................................... 102General: Center for Applied Research in Industrial and Systems Engineering ........................................................................... 104General: Key Characteristics in Manufacturing and Maintenance.............................................................................................. 106iv vi

Research and Technology 1998CONTENTS (cont)General: Searchable Answer Generating Environment — A Knowledge Management System ToSeek Experts in the Florida State University System .................................................................................................... 108Process Analysis and Modeling: Statistical Process Control Techniques for Variable Shuttle System Performance Data .......... 110Process Analysis and Modeling: Intelligent Assistant for Optimization Modeling .................................................................... 112Process Analysis and Modeling: Vision Spaceport Model Development ..................................................................................... 114Process Analysis and Modeling: Intelligent Synthesis Environment .......................................................................................... 116Process Analysis and Modeling: Virtual Shuttle Processing Model ............................................................................................ 118AUTOMATION AND ROBOTICS .............................................................................................................................................. 119Advanced Life Support Automated Remote Manipulator (ALSARM) ......................................................................................... 120Advanced Payload Transfer Measurement System (APTMS) ...................................................................................................... 122Automated Umbilical Mating Technology ..................................................................................................................................... 124Payload Ground Handling Mechanism (PGHM) Automation ..................................................................................................... 126Cable and Line Inspection Mechanism (CLIM) ............................................................................................................................. 128OmniBot Mobile Base .................................................................................................................................................................... 130Electro-Mechanical Actuator ......................................................................................................................................................... 131Solid Rocket Motor (SRM) Stacking Enhancement Tool (SSET) .................................................................................................. 132ELECTRONICS AND INSTRUMENTATION ....................................................................................................................... 135Space Shuttle Integrated Vehicle Health Management (IVHM) Flight Experiment ..................................................................... 136Orbiter Jack and Leveling Operations ............................................................................................................................................. 138Leak Detection and Visualization Using Laser Shearography ........................................................................................................ 140Support of the Linear Aerospike SR-71 Experiment (LASRE) ........................................................................................................ 142Ferroelectric Camera for Infrared Fire Imaging ............................................................................................................................... 1446U VME Universal Signal Conditioning Amplifier (USCA) Interface Module ........................................................................... 146Medical Aeronautical Communications System ............................................................................................................................. 147Portable Magnetic Field Sensor for Measuring Lightning Effects ................................................................................................. 148Inline Gas Analyzer for Cryogenic Hydrogen ................................................................................................................................ 150Space Shuttle Orbiter to External Tank Mating Tool ..................................................................................................................... 152Main Three Contamination Monitoring Cart ................................................................................................................................ 154Thermographic Inspection of Subsurface Voids in Composite Structures ...................................................................................... 156Automatic Calibration Station for the Universal Signal Conditioning Amplifier (USCA) .......................................................... 158v/vi vii

Research and Technology 1998Technology Programsand CommercializationIntroductionJohn F. Kennedy Space Center (KSC) maintains avigorous applied development program in support ofits designation as the NASA Center of Excellence forLaunch and Payload Processing. In accordance withthis mission, KSC is establishing its Spaceport TechnologyCenter (STC) that supports the development andutilization of technologies required to access space.The STC is composed of three pillars, Launch andLaunch Vehicle Processing Systems, Payload andPayload Carrier Processing Systems, and Landing andRecovery Systems. The STC forms the foundation forKSC’s growth into its future role as a developmentcenter for support of the Nation’s increasingly commercialspace initiatives. Having focused historicallyon applied development programs supporting industrial-leveloperations and processes, KSC technologyand expertise are uniquely suited to support the developmentof commercial products and services. Bothrapid-turnaround problemsolving and design techniquesand long-term investment in critical operationstechnology form the core of KSC’s research and developmentprograms.KSC aggressively seeks industry participation inits research initiatives and proactively seeks to transferits innovative expertise and technology to commercialspace initiatives and the nonaerospace commercialsector. Programs and commercialization opportunitiesavailable to American industry and other institutionalorganizations are described in the Technology Programsand Commercialization Office Internet Web siteat http://technology.nasa.gov.vii/viii ix

Research and Technology 1998LifeSciencesThe Life Sciences research andtechnology program at the JohnF. Kennedy Space Center (KSC)primarily supports the development ofadvanced technologies for applicationin life support for long-term humanhabitation in space. The near-termfocus of the Advanced Life Support(ALS) project is biomass productionimprovement, resource recovery development,and system engineering.Plant Gravitational Biology is investigatinglighting and nutrient-deliveryhardware systems, the effects of environmentalconditions (i.e., carbondioxide and temperature) on plantsgrowing in flight-type chambers, andmicrogravity effects on plant growthand development. These efforts aredirected toward evaluating and integratingcomponents of bioregenerativelife support systems and investigatingthe effects of a space environment onphotosynthesis and carbon metabolismin higher plants.1

Life SciencesCandidate Crop Evaluation forAdvanced Life Support andGravitational Biology and EcologyRice cv. Ai Nan Tsio (grown in the BPC to determine the effectof atmospheric contaminants on productivity and suitabilityfor advanced life support applications)The primary objective of this task is to defineenvironmental conditions and horticulturalmethodologies to optimize edible biomass productionin candidate crop species. This task includescoordination of NASA-supported tasks at the NewJersey NASA Specialized Center of Research andTraining (NJNSCORT) for tomato and salad crops,at the Tuskegee Institute for peanut and sweetpotato, at Utah State University for wheat andsoybean, and at NASA Research Announcement(NRA) grant recipients for other candidate crops.This task involves the screening of different cultivarsand the compilation of all crop growth data forinclusion in a crop handbook. This effort will use astandardized testing procedure for all candidatecrop species that were selected from the CropSelection Meeting held at KSC in May 1997. Thistask will develop crop management strategies forreuse of nutrient solutions with a special emphasison biologically active organic materials that mayaccumulate in the nutrient solution.The development of a bioregenerative lifesupport system requires that the horticulturalmethodologies and the range of suitable environmentalconditions for various candidate crops bewell understood. This is an integrated activityrequiring coordination with several research organizationsand ongoing Advanced Life Support (ALS)tasks in order to maximize the benefit to the ALSprogram.The candidate crop research and technologydevelopment conducted at KSC during 1998 included:2

Research and Technology 1998• Rice: A large-scale test of rice,cultivar Ai Nan Tsio, obtainedfrom Utah State University,was evaluated in the BiomassProduction Chamber (BPC)under filtered and unfilteredatmospheres (see the figure).• Dry Bean: Tests to determinethe suitability of a dry bean(Etna) and snap bean (Hystyle)for hydroponic productionunder elevated carbon dioxideconditions were initiated incollaboration with CornellUniversity.• Radish: Tests to determine theeffect of narrow-band spectralradiation delivered throughlight-emitting diodes (LED’s)were initiated in collaborationwith the ALS lighting task.• Chard: Tests were conductedin collaboration with thenutrient delivery task to comparethe results of the nutrientfilm technique to solid substrates,including variouszeolite formulations.• Table Beet: Tests were conductedin collaboration withthe National Research Council(NRC) on the ability of tablebeet to accumulate sodium(Na) in the leaf tissue.• Spinach: Tests to determine theeffect of narrow-band spectralradiation delivered throughLED’s were initiated in collaborationwith the ALS lightingtask.• Sweetpotato: A comparison ofthe nutrient managementsystem developed at KSC wascompared with that ofTuskegee Institute.• White Potato: Tests wereconducted in collaborationwith the ALS lighting task todetermine the maximumamount of light that can beperceived by potatoes duringthe dark cycle without inhibitingtuber formation.• Wheat: Tests were conductedin collaboration with theresource recovery-water recoverytask to determine the effectof gray water additions to thenutrient solution on growthand development of wheat.• Lettuce: Tests were conductedin collaboration with theresource recovery-water recoverytask, to determine the effectof gray water additions to thenutrient solution on growthand development of lettuce.Key accomplishments:• 1997: ALS program CropSelection Meeting hosted byKSC in May. Candidate croptesting in the BPC test bed ofthe Breadboard Project wascompleted in December.• 1998: Nine peer-reviewedarticles were either publishedor accepted for publication.Key milestones:• 1999: First edition of thehandbook for ALS candidatecrops.• 2000: 100-percent improvementin productivity of soybeanand peanut.Contact: Dr. J.C. Sager (John.Sager-1@ksc.nasa.gov), JJ-G, (407) 853-5142Participating Organizations: DynamacCorporation (Dr. G.W. Stutte), UtahState University (Dr. B. Baugbee),Cornell University (D. DeVillers), NRC(Dr. G. Subbarao), and TuskegeeUniversity3

Life SciencesPlant Nutrient Delivery SystemsDuring long-term space missions, a reliablenutrient delivery system (NDS) is required tocultivate plants that yield a satisfactory quantity ofedible biomass. Many plant nutrient deliverysystems used on Earth will not function effectivelyin space. An effective plant nutrient deliverysystem for spaceflight must provide adequateamounts and uniform distribution of water, nutrient,and oxygen in the root zone, while at the sametime, prevent release of free nutrient solution to theatmosphere. The ultimate goal is to design a nutrientdelivery system that is capable of sustainingplants for long periods under spaceflight conditionsyet requires minimal system maintenance andlimited demands on crew time. For extended plantcultivation in space, root-zone media will requiremore than just an initial loading of water andnutrients due to losses from plant evapotranspirationand nutrient uptake. Recent plant testing forspaceflight has begun to explore active nutrientdelivery concepts in which water and nutrients arereplenished on a continuous basis for long-termplant growth. At KSC, a series of ground-basedtests are being conducted on various recirculatingnutrient delivery systems that are proposed forextended space expeditions. The merits of eachnutrient delivery system are largely based upon theperformance of different shoot and root-zone cropsin terms of edible biomass yield from completegrowth cycles. To date for several crop species,these nutrient delivery systems were characterizedwith respect to plant water use, ion uptake, andnutrient solution pH changes over time.Key accomplishments:• Developed and tested recirculating nutrientdelivery systems that accommodate a range ofshoot and root-zone crops.• Explored nutrient buffered concepts to simplifysystem management, particularly for spaceflight.• Developed a protocol for continuous salad cropproduction for the Lunar-Mars Life Support TestProject Phase III at Johnson Space Center andconducted comparative studies with salad cropswith zeoponic media, porous tubes, and nutrientthin-film hydroponic nutrient delivery systems.Contacts: Dr. W.M. Knott (William.Knott-1@ksc.nasa.gov),Dr. J.C. Sager, and Dr. R.M. Wheeler; JJ-G; (407) 853-5142Participating Organization: Dynamac Corporation(Dr. G.D. Goins)ASTROCULTURE (Subirrigated Porous Tube System) RootTray With Lettuce Plants at 8, 15, and 22 Days After Seeding inARABASKETS Filled With Zeoponic Growing Media4

Research and Technology 1998Plant Lighting SystemsAmajor challenge to growingplants in space will be controllingand supplying sufficientquantity and quality of light. Theprimary objective of this task is tosignificantly improve the efficiencyof converting electricalenergy into edible plant biomass.Technology development effortsare focusing on obtaining lightsources to increase electricalconversion efficiency of lightingsystems and methods of collecting,transporting, and distributionof photosynthetically activeradiation (PAR) to the cropcanopy. Current research includesinvestigations of lightsources and methods that deliverPAR to crop plants that willproduce food for the space inhabitants.Two new sources thatshow great promise in deliveringPAR to the plant canopy includemicrowave lamps and lightemittingdiodes (LED’s). Microwavelamps are a new technologythat use microwave energy toenergize an electrode-less sulfurfilledelement. It has a spectralMature USU-SuperDwarf Wheat Plants Growing Under an Array of600-Nanometer Red Aluminum-Gallium-Arsenide (GaAlAs) LED’soutput similar to other high-intensity discharge sources but uses 20 to30 percent less energy for comparable output. LED’s are a promisingelectric light source for space-based plant growth chambers andbioregenerative advanced life support because of their small mass andvolume, solid state construction, safety, and longevity.Key accomplishments:• Completed LED experiments with different food crops to investigatecarbon exchange and stomatal conductance differences betweenlight treatments and species.• Determined low-level irradiance requirements during the darkperiod for photoperiodic-induced tuberization of potato.• Evaluated solid-state magnetron microwave lamp systems.Contacts: Dr. W.M. Knott (William.Knott-1@ksc.nasa.gov), Dr. J.C. Sager, and Dr.R.M. Wheeler; JJ-G; (407) 853-5142Participating Organization: Dynamac Corporation (Dr. G.D. Goins, N.C. Yorio,and G. Koerner)5

Life SciencesMicrobial Ecology of BioregenerativeLife Support Systems for Space ExplorationThe stability of microbial communitieswithin closed bioregenerativesystems is an importantcomponent of overall systemstability due to the risk of humanor plant disease and the reliance onmicrobially based reactors for wasteprocessing. Effective managementof microbial communities requiresan improved understanding of thecomplex interactions among microorganismswithin Advanced LifeSupport (ALS) systems that, in turn,depend on advancements in rapidand reliable monitoring techniques.The purposes of this work are todevelop monitoring tools that allowfor a better understanding of themicrobial risks associated withbioregenerative life support systemsand to evaluate the suitability ofthese tools for use in Moon or Marsbases. Experiments with prototypeALS subsystems under developmentat KSC (e.g., plant productionsystems and bioreactors) will assessthe ability of different techniques toidentify changes in the overallstability of microbial communitiesand detect the presence of specifichuman or plant pathogens beforethe health of the system is adverselyaffected. These efforts will helpidentify the best approaches formanaging microbial risks within thesystems in addition to evaluatingspecific sensor technology.The primary effort this yearinvolved the development ofadvanced analytical software for arapid, simple monitoring methodbased on functional profiling ofmicrobial communities. Thisapproach, which was developed bythe Dynamac staff, detects respirationof 95 separate carbon sourcesusing a redox sensitive dye. Initialtesting indicated that the community-levelphysiological profiles(CLPP’s) can detect small changesin microbial communities associatedwith prototype ALS systems. Thenew software enables automatedanalysis of the kinetic profile of dyereduction for each of the 95 separatecarbon sources based on nonlinearregression. The parameters of thenonlinear curve (lag, maximumrate, asymptote, and integral) can beautomatically exported into thestatistical software for subsequentmultivariate analysis.Another major effort this yearinvolved assessment of the effects ofbacterial diversity (the number andrelative abundance of bacterialtypes) in prototype ALS systems onthe survival of introduced opportunistichuman pathogens. Ecologicaltheory suggests that greater diversitymay decrease the likelihood ofpotentially deleterious organisms,such as opportunistic humanpathogens, from growing in microbialhabitats within ALS systems. Incollaboration with scientists fromthe University of South Florida, theUniversity of Virginia, and MichiganState University, the relativesurvival of opportunistic humanpathogens in systems with differentlevels of diversity was evaluated.Such studies will be important indefining effective approaches forinoculating bioregenerative lifesupport systems.A third focal area involved thedevelopment of molecular tools forassessing microbial communities inbioregenerative ALS. Severalprofiling techniques based on thedetection of genetic variation withinbacterial communities were used tocharacterize ALS systems, includingTerminal Restriction FragmentLength Polymorphisms (T-RFLP’s),Randomly Amplified PolymorphicDNA (RAPD), and AmplifiedFragment Length Polymorphism(AFLP). All of these methodsinvolve amplification of genes usingthe polymerase chain reaction(PCR). T-RFLP analyses wereperformed at Rutgers Universitywhile the other approaches wereperformed at KSC in collaborationwith the University of Virginia.Key accomplishments (1998):• Submitted a new technologyreport for the CLPP technique.• Developed the CLPP analysissoftware.• Completed the report comparingthe effectiveness of the differentanalytical approaches on classifyingmicrobial communities fromplant production systems andbioreactors.• Completed studies evaluating theeffect of community diversity onthe survival of human pathogensin plant production systems andbioreactors.• Completed the analysis andpreliminary report on T-RFLPanalysis of samples from ALSbiomass production systems.• Established molecular microbialecology facilities at KSC andcompleted the preliminaryanalysis of ALS samples usingRAPD and AFLP.Key milestones (1999):• Complete the testing of the CLPPsoftware, including the publicationof the results and the distributionof the product to interestedresearch organizations.• Expand the molecular microbialecology infrastructure at KSC,including the purchase of a DNAsequencer.6

Research and Technology 1998• Develop and test miniaturized biosensors basedon bioluminescent bioreporter integrated circuit(BBIC) technology in collaboration with theUniversity of Tennessee.• Complete the initial assessment of the effects ofdiversity on the microbial risks associated withthe growth of opportunistic human pathogens.Contact: Dr. J.C. Sager (John.Sager-1@ksc.nasa.gov), JJ-G, (407)853-5142Participating Organizations: Rutgers University (Dr. L. Kerkhof),University of Virginia (Dr. A. Mills), University of Tennessee(Dr. G. Saylor), University of South Florida, Michigan StateUniversity, and Dynamac Corporation (Dr. J. Garland)1.8A1.61.41.210.8µ mNonlinearRegression(x 95)0.60.40.2λ00 20 40 60 80 100 120Monitoring/ControlRapidMetabolicProfilingMicrobial Systems(Bioreactors, Plants)Microbial Monitoring for the ALS7/87

Research and Technology 1998MechanicalEngineeringThe Mechanical Engineering programat the John F. Kennedy Space Center(KSC) supports the development oftechnology with analysis, design, andoperation of launch and ground supportequipment for space flight vehicles.Technology is advanced by a broadvariety of analysis including structuraldeflection, dynamic response, stress,dynamic data requirements, reduction,and processing. Also included are singleand multiphase flow, cryogenic fluidflow and storage, thermal insulationdevelopment, and fracture mechanics.Launch-induced environments are predictedand evaluated with test spectra,modal testing, portable dynamic dataacquisition, and analysis. MechanicalEngineering also covers system andmechanism troubleshooting, componenttesting, and development of tools, devices,and systems for fabricating systemsand obtaining required cleanliness.9

Mechanical EngineeringInsulation Testing Using a Cryostat Apparatus With SleeveThe method and equipment oftesting continuously rolledinsulation materials was developedat the KSC Cryogenics TestLaboratory in 1998. The testing ofblanket and molded products isfacilitated by the technology.Materials are installed around acylindrical copper sleeve using awrapping machine. Large sizeinsulation test articles that are6.69 inches inside diameter by 36inches long by up to 2 inches inthickness can be fabricated andtested. The sleeve is slid onto thevertical cold mass of the cryostat.The gap between the cold massand the sleeve measures 0.035inch. The cryostat apparatus (seefigure 1) is a liquid nitrogenboiloff calorimeter system thatTemperature (kelvin)350300250200150100500Cold Mass Sleeve Layer 2(0.106”)Layer 4(0.212”)LayersLayer 8(0.424”)Layer 18(0.953”)Figure 2. Layer Temperature Profiles for Different Vacuum Levels(Cryostat 1, Test Series C114)CVP=0.13CVP=10CVP=100CVP=1000CVP=10000Shroudenables direct measurement of the apparent thermalconductivity (k-value) of the insulation system at anyvacuum level between 5x10 -5 and 760 torr.Figure 1. Cryostat Apparatus — Liquid NitrogenBoiloff Colorimeter SystemSensors are placed between layers of the insulation toprovide complete temperature-thickness profiles. Thetemperatures of the cold mass [maintained at 77.8 kelvin(K)], the sleeve [cold boundary temperature (CBT)], theinsulation outer surface [warm boundary temperature(WBT)], and the vacuum chamber (maintained at 315 K bythe thermal shroud) are measured. Layer temperatureprofiles as a function of the vacuum level, as shown infigure 2, indicate the three ranges (radiation, gas conduction,and convection) of dominant heat transfer modes.Heat leak through to the ends of the cryostat is reduced toa negligible amount by the use of liquid nitrogen filledchambers on the top and bottom. The cryostat apparatusis supplied with liquid nitrogen subcooled to approximately77.8 K. The upper guard chamber is kept at aslightly higher pressure (0.150 ±0.050 pound per squareinch differential) than the test chamber to preclude thecondensation of any boiloff gas as it is exiting through thecenter of the guard. During the boiloff replenish phase,10

Research and Technology 1998the guard chambers must be maintained at 0.6 ±0.1 pound per squareinch gage for minimum heat leak. Steady-state boiloff conditions areachieved in 6 to 12 hours after an initial chilldown and thermal stabilizationperiod of at least 24 hours. Typical plots of flow rate andk-value are shown in figure 3. (Note that the end of the first plateau isthe point at which the replenish of the guard chambers is terminated.)The vacuum pumping system consists of a combination ofturbopumps and mechanical pumps plus a finely metered gaseousnitrogen supply for controlling the pumping speed. All measurementsare recorded on a National Instrument Field Point data acquisitionsystem using LabView software.Flow (standrd cubic centimeters per minute)800700600500400300200100Flowk04 5 6 7 8 9 10 11 12Time (hours)Figure 3. Liquid Nitrogen Boiloff Test Perfomance[Cryostat 1, Test Series C114, Run 10 (0.1 micron)]Thermal Conductivity - k (milliwatt per meter-kelvin)For this cryostat apparatus,the measurable heat gainis from 0.2 to 20 watts (whichcorresponds to a boiloff flowrate of 50 to 5,000 standardcubic centimeters perminute). The surface area fora typical 1-inch-thick insulationtest article is 969 squareinches. The steady-statemeasurement of the insulationperformance is madewhen all temperatures andthe boiloff flow are stable.The k-value of the insulationis directly computed from theboiloff rate, the cold massgeometry, and the deltatemperature (WBT-CBT).Contact: J.E. Fesmire (James.Fesmire-1@ksc.nasa.gov), MM-J2,(407) 867-7969Participating Organization:Dynacs Engineering Co., Inc.(S. Augustynowicz)11

Mechanical EngineeringDevelopment of a Multipurpose Cryostatfor Insulation TestingAmultipurpose cryostatapparatus (Cryostat-2) wasdesigned and fabricated at theKSC Cryogenics Test Laboratory.The apparatus can be used fortesting insulation materials orcryogenic couplings and seals.Using custom handling fixtures,the inner assembly is easily andquickly removable for installationon an 18-inch-wide insulationwrappingmachine. Alternatively,the lower thermal guard can beremoved for the testing of flatplateconfigurations. The stainless-steelinner vessel is a cylinder5.2 inches in diameter by 10.5inches in length. The overalldimensions of the vacuum chamberare 12 inches in diameter and26 inches in length. The figureshows the inner assembly on itswork stand adjacent to thevacuum chamber assembly.Thermal guarding of each end isprovided by a 5-inch-diameter by5-inch-long stack of aerogelcomposite disks with silveredfilm layers between each disk. Asingle 1/2-inch diameter by 19-inch-long fluid feed-throughconstructed from thin-wallbellows and a VCR couplingallow for liquid nitrogen filling,venting, and boiloff. The entireinner assembly is suspended bythree Kevlar threads that areattached to the flange of thevacuum chamber. The designmaximum heat leak for thesystem is 0.025 watt at a highvacuum level to 0.050 watt at asoft vacuum level. The surfacearea for a typical 1-inch-thickinsulation test article is 969square inches. The measurableheat gain is estimated to be from0.100 to 40 watts (which correspondsto a boiloff flow rate of 25to 9,666 standard cubic centimetersper minute). The operatingtemperature range is 77 to 373kelvin while the operating pressurerange is 1x10 -6 torr to 1,000torr. Cryostat-2 is currently beingused for testing continuouslyrolled insulation materials.Contact: J.E. Fesmire (James.Fesmire-1@ksc.nasa.gov), MM-J2, (407) 867-7969Participating Organization: Dynacs EngineeringCo., Inc. (S. Augustynowicz)12

Research and Technology 1998Cryogenics TestLaboratoryThe KSC Cryogenics TestLaboratory is located at theNASA Development TestingLaboratory (Building M7-581). Avariety of industry, aerospace,and research activities in the areaof cryogenics and propellantsystems is supported. Theseactivities include design, fabrication,testing, analysis, field testing,and engineering evaluation.The laboratory facilities include aliquid nitrogen flow test area, avalve test cell, a high-vacuumworkstation, and a liquid nitrogenboiloff calorimeter (Cryostat-1). Cryogenic insulation systemdevelopment is the main line ofwork at this time. The areas ofexpertise include:• Cryogenic insulation systems• Cryogenic valves and devices• Connectors, seals, and sealmaterials• High vacuum and leakage• Design concepts and prototypefabrication• Flow testing and analysisPlans for 1999 include:• Activation of a multipurposecryostat apparatus (Cryostat-2)• Conversion to National InstrumentsFieldPoint data acquisitionsystems• Addition of instrumentationand controls to the flow testarea• Enhancement of valve test cellThe renovation of a 5,000-square-foot facility to house test,checkout, and research activitiesis also being planned for completionin late 1999.Contact: J.E. Fesmire (James.Fesmire-1@ksc.nasa.gov), MM-J2, (407) 867-7969Participating Organization: DynacsEngineering Co., Inc. (S. Augustynowicz)13

Mechanical EngineeringVerification TestArticle ProjectDuring a Shuttle launch,ground support equipmentand structures in the proximity ofthe launch pad are subjected tointense vibration due to acousticpressure generated by rocketexhausts. Continuous monitoringof launch-critical loads (acoustics)and simultaneous structuralresponse (vibration and strain) isvital for design of new andproactive maintenance of existingstructures. By the end of 1996,the collection of acoustic, vibration,and strain data from sevenlaunches from Launch Pad 39Awas completed on a cantileverbeam, called the Verification TestArticle (VETA). Analyzed datafrom these launches was crucialfor validating a random vibrationresponse model based on thedeterministic approach developedat KSC. A detailed reportoutlining the validation methodologywas released in 1997.VETA measurements provedextremely valuable in characterizingtwo separate zones of acousticloading on the ground supportequipment. Tests showed theliftoff peak acoustics (betweenT+2 to T+7 seconds) are oftenovershadowed by a significantsecondary peak (between T+10and T+17 seconds). This secondpeak, the “plume impingement”peak, is directly attributable tothe Shuttle roll maneuver. Theliftoff peak is composed primarilyof high-frequency componentsabove 50 hertz. The secondaryplume impingement effect contributessignificantly to thestructural resonances because ofits low-frequency composition.Limited launches and failedsensors restricted analysis effortsto evaluate effects of launchtrajectory, multimodal contribution,and effects of higher modeson the overall response andprediction confidence intervals.Key accomplishments:• 1998: Several lectures onrocket noise and vibration werepresented at the Universities ofPerth and Adelaide in Australia.The acoustibox conceptwas tested on several launchesand results were positive. Torecord launch-induced acoustics,a totally self-containedacoustibox (operates on batteries)was installed on the launchpad and has (1) the capabilityto “wake up” prior to launchand to store the recorded dataand (2) postlaunch retrievalsoftware.Key milestone:• 1999: Efforts will be aimedtoward developing a totallyindigenous unit for use by KSCoperations, in line with NASApolicy of “better, faster,cheaper.”Contact: R.E. Caimi (Raoul.Caimi-1@ksc.nasa.gov), MM-J2, (407) 867-3748Participating Organizations: DynacsEngineering Co., Inc. (R.N. Margasahayam),United Space Alliance(F. Walker), and Information Dynamics,Inc. (O. Varosi and L. Albright)14

Research and Technology 1998Self-Contained Acoustibox on the Launch Pad15

Mechanical EngineeringLiquid Nitrogen Feed System and Subcooler for the CryostatAspecial liquid nitrogen feedsystem for the insulation testcryostat (Cryostat-1) was designedand constructed at theKSC Cryogenics Test Laboratory.The cryostat requires a stablesupply of liquid nitrogen near thenormal boiling point (77.36 kelvinat atmospheric pressure) for runtimes of up to 12 hours. The feedsystem consists of an adjustablepressure phase separator (APPS)unit, a 1/2-inch vacuum-jacketedpipeline with cryo-vent devices,and a subcooler unit. The APPSunit maintains a supply of liquidnitrogen saturated at 19 ±1 poundper square inch gage and allowsinsulation testing to be performedindependent of other tests usingthe main supply dewar. Thesubcooler unit provides 11 ±0.5pound per square inch gageliquid nitrogen conditioned atapproximately 77.8 kelvin to thecryostat inlet manifold. Theliquid reservoir of the subcoolerconsists of a stainless-steel vessel10.75 inches in diameter by 24inches tall that is enclosed by anouter shell. The annular space isfilled with excess liquid from theinner vessel and vented to theatmosphere. The levels in theliquid reservoir and outer shellare maintained by an adjustmentof a control valve from the mainsupply line. Tube fittings on thetop allow for simple installationor removal. The exposed fittingsare quenched in the liquid nitrogenoverflow from the outer shellto eliminate a heat leak. Anoverall view of the subcooler unitis shown in the figure.Contact: J.E. Fesmire (James.Fesmire-1@ksc.nasa.gov), MM-J2, (407) 867-796916

Research and Technology 1998Liquid Nitrogen FlowTest AreaThe liquid nitrogen flow testarea was activated at the KSCCryogenics Test Laboratory. Thearea includes a 6,000-gallondewar that supplies liquid to lowflowand high-flow test sections.The low-flow section, fed by anadjustable pressure phase separatorand a 1/2-inch vacuumjacketedpipeline, can provide 0to 100 pounds per square inchgage at up to15 gallons perminute. An inline density meterbuilt by Dynacs Engineering Co.,Inc., is included to monitor flowconditions and transients duringa test. The high-flow sectionincludes run piping with 3-inchand 6-inch diameter test sectionsthat are adaptable to any sizecomponent up to a 12-inch nominalpipe size. The high-flowsection provides flow rates of upto 1,000 gallons per minute at 250pounds per square inch gage.Instrumentation and controls aretailored to the requirements for agiven test using the new NationalInstruments FieldPoint equipmentand LabView software forthe data acquisition system. Anoverall view of the test area isshown in the figure.Contact: J.E. Fesmire (James.Fesmire-1@ksc.nasa.gov), MM-J2, (407) 867-7969Participating Organization: DynacsEngineering Co., Inc. (Z. Nagy)17

Mechanical EngineeringAnalysis of Nonstationary Signals UsingWavelets for Extracting ResonancesTo determine the frequencycomposition of a signal formechanical analysis, signalprocessing tools such as the FastFourier Transform (FFT) and theShort Time Fourier Transform(STFT) are used. However, theuse of Fourier analysis for frequencycomponent extraction isrestricted to band-limited stationarysignals. Thus, small transientsmay not be detected due toa smoothing effect of the FFT, orthe FFT spectrum may besmeared due to frequency rampingor discontinuities in thesignal. Space Shuttle launchinducedacoustic and vibrationsignals can be classified asnonstationary random andexhibit features of a very shortduration transient. Varioustechniques have been employedto overcome the limitations of theFFT for nonstationary data.These techniques include windowedFourier Transform (Gaboror STFT), synchronous samplingto remove revolutions-per-minuteramp effects, Wigner-Ville analysis,and wavelet analysis.Wavelet analysis is based on afundamentally different approachin which the signal is decomposedon a series of special-basisfunctions called wavelets, whichare localized in time and have anintegral value of zero. Waveletanalysis can pinpoint local phenomenain nonstationary signalsand provide the capability tocompress or de-noise a signalwithout appreciable degradation,while preserving both highfrequencyand low-frequencycomponents. Wavelet techniquescan be extended to detect andanalyze impending bearingfailure in rotating machinery (seethe graphs). Planned developmentswill use the MATLABplatform, a commercially availablesoftware.Key accomplishments:• 1998: The wavelet analysismethods were applied to SpaceShuttle launch-induced acousticand vibration signals tohighlight key low-frequencycomponents affecting structuralresonance. The waveletanalysis methods were appliedto liquid oxygen pump rotatingmachinery analysis for conditionmonitoring, machinediagnostics, and bearing faultdetection and prediction.Key milestones:• A comparative evaluation ofthe FFT and wavelets isplanned. Effectiveness ofdifferent wavelet techniqueswill be studied.Contact: R.E. Caimi (Raoul.Caimi-1@ksc.nasa.gov), MM-J2, (407) 867-3748Participating Organizations: DynacsEngineering Co., Inc. (R.N. Margasahayam)and Information Dynamics,Inc. (O.J. Varosi)18

Research and Technology 1998Stationary FailureOnset ofNonstationaryFailureTime Domain Signal for Impending Bearing FailureSteady StateBefore FailureMalvar DWTUseful DuringNonstationaryIntervalFFT NotUseful DuringNonstationaryIntervalComparison of DWT and FFT19/20

Research and Technology 1998EnvironmentalEngineeringThe John F. Kennedy Space Center(KSC) is located on the MerrittIsland National Wildlife Refuge.Therefore, KSC has always approachedits mission with an awarenessof the impact on the environment. As asociety, Americans have become increasinglyconcerned about the effect their actionshave on the environment. With thisawareness, KSC has increased its efforts to develop technologiesthat are environmentally oriented and proactive.The projects presented this year cover a wide range of environmentaltechnologies. An innovative method of scrubbing emissionsfrom boilers is being developed that will reduce the amountof pollutants produced by power plants that burn fossil fuels. Alsounder development are methods to clean solvent-contaminatedgroundwater using in situ techniques that could reduce cleanupcosts significantly.Another area of interest is the geographical information requiredto make environmental decisions. A development is continuingto integrate geographical databases that provide easy access to thedata used for planning purposes.A project to plan controlled burns is also underway. The burns arean important tool for restoration of endangered species habitat andreduction of the danger of wildfire in operational areas.21

Environmental EngineeringHabitat Management and Ecological RiskAssessment ModelingMonitoring and definition ofhabitat quality forbiodiversity, threatened andendangered species, and environmentalrisk assessment requirestate-of-the-art informationcollection and analysis capabilitiesto minimize costs. Landmanagement practices in manyecosystems, including KSC, arebased on controlled burning forhabitat enhancement and reductionof wildfire fuels. Availableecosystem models and fire andsmoke models provide someguidance; however, no systemcurrently exists that incorporatesthese tools with operationalschedules such as a payload orvehicle processing system, realtimemeteorological data, andremote sensing data for use inenvironmental decision supportand risk assessment.The approach to this projectinvolves development of a diverseset of information toolsincluding rule-based expertsystems, numerical models, timeseries analysis, and fusion of avariety of data collection systemsand databases to enhance thedecision process. The projectwill:• Provide data and informationto optimize the management ofresources at KSC and theMerritt Island National WildlifeRefuge.• Incorporate NASA remotesensing and advanced GIStechnology into local-scale,decisionmaking processes.• Provide information andmethods to reduce the potentialfor wildfires at KSC.• Enhance NASA’s capabilities tocomply with Federal and Stateenvironmental laws such as theEndangered Species Act.Key accomplishments:• 1996: Obtained a high spectralresolution image of the KSCarea using the NASA AVIRISsensor. Initiated developmentof a deterministic model forestimating plant canopy biochemicaland biophysicalcharacteristics.• 1997: Conducted an experimentalcontrol burn at KSC inassociation with the U.S. Fishand Wildlife Service, LosAlamos National Laboratory,United States Air Force, andLos Angeles County FireDepartment to develop data onfire spread, intensity, andsmoke production. Obtainedhigh spatial resolution images(1 to 2 meters) of KSC. Obtainedfield measurements ofplant canopy biophysical andbiochemical features and plantcanopy and leaf spectralcharacteristics for modeldevelopment and parameterization.• 1998: Developed a Web-baseddecision support tool thatintegrates payload schedules,Shuttle operations schedules,facility locations, and controlledburn prescriptions tominimize conflicts and maximizemanagement of wildfirefuels and endangered wildlifehabitat. Integrated plantbiophysical features such asleaf area, leaf angle distribu-22

Research and Technology 1998tion, canopy closure, canopy height,and bottom reflectance into a two-flowirradiance model for radiative transferin plant canopies.Key milestones:• 1996: Initiated GIS database integrationin Oracle and development ofimage processing methods for use ofhigh spectral resolution data in wildlifehabitat mapping. Presented twopapers at the Eco-Informa Conferencein Orlando, Florida, on remote sensingmodeling in plant canopies.• 1997: Coordinated a multiagencyexperimental controlled burn to obtaindata on fire and smoke behavior incoastal environments.• 1998: Enhanced communicationsbetween the U.S. Fish and WildlifeService and NASA Shuttle and PayloadsOperations through developmentof a Web-based Schedule AnalysisSystem for controlled burns at KSC.Contact: Dr. W.M. Knott (William.Knott-1@ksc.nasa.gov), JJ-G, (407) 867-7411Participating Organization: DynamacCorporation (R. Schaub and C. Hall)Example Output From the Web-Based Decision Support Tool ShowingIntegration of Fire Management and KSC Operational Areas• Individual controlled burn events are plotted on separate maps.• Only facilities with potentially critical smoke-sensitive operationsare plotted.• Half-mile buffer zones are plotted around each potentiallycritical smoke-sensitive operation to facilitate viewing of thelarge-scale map.• Shuttle operations occur within the Shuttle Landing Facility,Vehicle Assembly Building, and launch pad regions.• Payload operations occur within the KSC Industrial Area andCape Canaveral Air Station Industrial Area.• The smoke management area defines the region in which smokemay occur based on desired winds (smoke may also occurdownwind of this area).23

Environmental EngineeringThreatened and Endangered Species MonitoringThe habitats on KSC representan area of biological diversityunsurpassed among Federalfacilities. Under the EndangeredSpecies Act and the NationalEnvironmental Policy Act, alloperations require evaluation andimpact minimization. Approximately100 wildlife species on theMerritt Island National WildlifeRefuge are vulnerable to extinction.Monitoring focuses oncombining field and remotesensing data with predictive/interpretive models on marineturtles, gopher tortoises, indigosnakes, wading birds, shorebirds,scrub jays, beach mice, andmanatees. These studies contributedto more than 20 scientificjournal articles and were used todevelop rangewide speciesrecovery efforts.The influence of habitat onhabitat use and demographicsuccess is quantified at differentspatial scales. Monte Carlosimulation models are used toquantify the influence of habitatquality, population size, andcatastrophes on populations.Declining habitat quality wasfound to be a critical factorinfluencing extinction risk, somore frequently prescribed firesare needed.Key accomplishments:• 1991: Developed habitat mapsof the most important areas atKSC for scrub jays, wadingbirds, and other species.• 1992: Developed a scrubrestoration and monitoringprogram.• 1993: Developed a wetlandsrestoration program plan.• 1994: Developed a KSC biologicaldiversity evaluationsummary.• 1995: Developed techniques tomap habitat suitability.• 1996: Developed models topredict demographic successusing maps.• 1997: Tested the ability ofmaps and models to predictpopulations.• 1998: Developed rapid assessmenttools for environmentalmanagers.Key milestones:• 1995: Population and habitatstatus trends summarized forgopher tortoise, wading birds,and scrub jays.• 1996: Development of scrubjay population recovery strategy.• 1997: Biological diversityprioritization analyses published.• 1998: Habitat analysis procedurespublished.Contact: Dr. W.M. Knott (William.Knott-1@ksc.nasa.gov), JJ-G, (407) 867-7411Participating Organization: DynamacCorporation (D.R. Breininger)24

Research and Technology 1998Height Classes of Florida Scrub Jay Territories at KSC From 1988 to 1997(Habitat classes are used for rapid assessment of scrub habitat quality.)Height ClassDescriptionMinimum Mapping UnitsShortShort/optimal mixTall mixTallEntire territory was 170 cm) and short and/oroptimal scrubEntire territory was >170 cm tallNo patch taller than 120 cm was≥0.4 hectare (ha) (1 acre)At least 1 patch of optimal scrubwas ≥0.4 ha and at least 1 patch ofshort scrub was ≥0.4 ha; no patchof tall scrub was ≥0.4 haAt least 1 patch of tall scrub was≥0.4 ha; at least 1 patch of short oroptimal scrub was ≥0.4 haNo scrub

Environmental EngineeringPilot-Scale Evaluation of a New Technology To Control NO xEmissions From Stationary Combustion SourcesTo ExhaustStack/Outside AirFlue GasBoiler No. 2InjectionReaction ZoneSamplesQuenchGas-to-LiquidScrubberExhaustSamplesconducted by UCF researchersindicated this technology wouldbe competitive with technology(selective catalytic reduction)currently available to powerplants if nitric oxide (NO) conversionefficiencies above 90 percentcould be achieved at a hydrogenperoxide feed rate of 1.37 molesof hydrogen peroxide per mole ofNO converted (to acid). ThePhase I results of this technologyshow 96 percent NO conversionswere achieved at a molar ratio of1.0.Key accomplishments:As a result of the implementationof the Clean Air ActAmendments of 1990, partiesresponsible for stationary combustionsources emitting nitrogenoxides (NO x) are looking formethods to meet regulatoryrequirements. NASA entered intoa 3-year cooperative agreementwith the University of CentralFlorida (UCF) to perform a pilotscalestudy of a new controltechnology for NO xemissionsfrom industrial-sized boilers (seefigure 1). Hydrogen peroxide isinjected into the flue gas streamto oxidize the NO xto nitrogenacids. This step is followed byliquid scrubbing, which producesa nitrogen-rich, water-basedwaste stream. This study was ascale-up on the order of 1,000times from lab-scale studiespreviously conducted at UCF. Ascale-up from this pilot plant to aFigure 1. Conceptual Design of the Systempower plant would be on thesame order of magnitude. NASAand UCF are joined by industrypartner EKA Chemicals, Inc., onthis research and developmentproject. EKA Chemicals brings tothe project extensive engineeringexpertise on various hydrogenperoxide applications.A data acquisition systemusing a personal computer andLabView software (see figure 2) istied into the entire system toallow for control, automaticemergency shutdown, and recordingof 21 points at a rate of 1sample per second. Over 100tests were conducted during thepast year resulting in over 6million data points.The primary result from thefirst phase of this study is shownin figure 3. A feasibility study• 1997: Phase I design, installation,and preliminary testingcomplete.• 1998: Phase I testing, dataanalysis, and reports complete.Presentations at the Air andWaste ManagementAssociation’s Pacific Northwestand Southern Statessection meetings.Key milestones:• 1999: Present Phase I results atthe Air and Waste ManagementAssociation’s annualconference. Phase II design,testing, data analysis, andreports to be completed.Contact: M.M. Collins (Michelle.Collins@ksc.nasa.gov), JJ-D, (407) 867-4270Participating Organizations: Universityof Central Florida (Dr. C.D. Cooper; Dr.C.A. Clausen, III; and Dr. J.D. Dietz)and EKA Chemicals, Inc. (J. Tenney andD. Bonislawski)26

Research and Technology 1998NOX Emission Reduction Test1BOILEREvent CounterThe event indicatorhas been depressedAux. NOBurnerT1 175.1 Deg F TI 1T1T3 174.9 Deg F T5 185.0 Deg F T7 161.4 Deg FT2T9 193.4 Deg FT3T5T7T9PC1CV12 3 4 5 6CV2CV1CV2CV11MFM MFM 76 SFPMTI 2NOX Flow0.11SLPMFC6FC3NO0 Vdc (5=On, 0=Off)0times during this run.Control PanelInput 0-100for percentage7CV2CV11 CV6 CV4CV7CV8CV3T11T4T6T8IMT4 180.0 Deg F T6 183.4 Deg F T8 168.1 TFMIDeg FWater SupplyTFM1 0.003 gpm T11 94.2Deg FSO2 Flow0.05 FC4SLPMGO 2Data FilenameFC-1File Name0 100.00 0.00 0.00 0.00 80.00 0.00Valve Act.FC-2NOX Flow% of F.S.FO4Water SupplyFC-3SO2 Flow% of F.S.FC-4Not UsedT10 110.4 Deg FFC-5Fan Speed% of F.S.VaporCircle SupplyFC-6NaturalGasBurner9SCRUBBERRecordSTOPALARMST10PHFC3Vent to OutsideFANVFD -0.0 %F.S.T11 CV11 P210P2 0.8 in W.C.F1TFM2TFM2-0.0 gpmH 2 O 2TANKW1 0.000 lbsT10P1P1 -0.1 in W.C.MI8????PH1 6.8 phOV14VaporWaterFigure 2. Front Panel of the PC Software Used To Collect Data From Points in the System100%% NO Conversion80%60%40%20%%NO Conversion0%0.0 0.5 1.0 1.5 2.0 2.5H 2 O 2 :NOFigure 3. Percent NO Conversions for Inlet NO x of 400 ppm andTests Conducted Within the Temperature Range of 912 to 939°F27

Environmental EngineeringConcentration (mg/L)120100806040200Development of an In Situ Technique for ElectrokineticRemediation of Soils Contaminated With Heavy MetalsBecause of the costs and limitationsof the current remediationmethods, considerable effortis being directed toward thedevelopment of in situ treatmentmethods. An innovative method,electrokinetic remediation, offersa way for soils with a variety ofhydraulic conductivities to beremediated in situ. Electrokineticshas been used for decades toremove water from soils and inthe oil recovery industry, but insitu applications to remediatecontaminated soils is new. Electrokineticsis a process thatseparates and extracts certainheavy metals, radionuclides, andorganic contaminants fromsaturated or unsaturated soils,sludges, and sediments. A lowintensitydirect current is appliedacross electrode pairs that havebeen implanted in the ground oneach side of the contaminated soilmass. The electrical currentEffect of Potential Effluent Concentrate(01/26/98 to 01/29/98, 20 V, 55 mA)lead zinc0 20 40 60 80Time (hours)Lead and Zinc Concentrations in Effluent With Applied Voltagecauses electroosmosis, ion migration,and electrophoresis, whichremoves bound ions from solidparticles and moves the aqueousphase contaminants in the subsurfacefrom one electrode to theother.Laboratory studies at theUniversity of Central Floridahave been used to evaluate theefficiency of this process and itslikelihood of success at KSC.Initially, studies were carried outin a 12-inch-long, 4-inch-diameterPlexiglas cell that was loadedwith 2,000 grams (dry weight) ofa synthetic soil mixture. The soilwas spiked with lead (Pb) andzinc (Zn) to concentrations up to2,000 milligrams per kilogram ofsoil, then the metals were immobilizedusing a sodium hydroxiderinse. Graphite electrodes (placedeither perpendicular or parallel tothe flow) were used with appliedvoltages ranging from 15 to 48volts and a constant current of100 milliamperes. A conditioningsolution of dilute lactic (0.1 to 0.5percent) acid was introduced atthe anode and removed at thecathode. This conditioning fluidserved as an additional liquid forcurrent flow and to keep the pHin an acceptable operating rangenear the cathode region.It was shown from theseexperiments that both Pb and Znwere quickly removed to 10percent of their original concentrations(within 7 days). A comparisonof the ion removal effi-28

Research and Technology 1998ciency with and without anapplied voltage is shown in thefigure. As voltage was applied,the concentrations of Pb and Znin the effluent solution increased.In another experiment, removalefficiency was shown to bedependent on the addition oflactic acid. With only water as aconditioning fluid, extractionefficiency was low but, with theintroduction of a very low concentrationof lactic acid (as low as0.1 percent), the ion concentrationsin the effluent solutionbegan to increase dramatically.The effects of electrode positionwere studied by constructinga rectangular cell and positioningtwo pairs of electrodes at differentdistances. Experiments haveshown that electrodes positioned18 to 22 inches apart providedeffective movement of ions invarious soil types. This informationwas used to develop themost efficient electrode arrangementfor a field application. Ahexagonal array of anodes with asingle cathode placed directly inthe center was found to yieldefficient removal of metal ionswhile reducing the number ofpumping stations (cathodes)required.Additionally, a telephone line,an extension cord, and varioustypes of weathered pipe wereburied in the soil for a period of 3weeks to determine if the processwould interfere with communicationsor other subsurface electricalconduits. During this time,there was no disruption of communicationor electrical use andthe pipes showed no pitting.Key accomplishments:• June 1998: Laboratory studieswere completed.• August 1998: Field demonstrationsite was selected at KSC.• September 1998: Field designwas completed.Key milestone:• Laboratory data used to designthe field demonstration wascompleted, with field implementationto begin in January1999.Contact: J.W. Quinn (Jacqueline.Quinn-1@ksc.nasa.gov), JJ-D, (407)867-4265Participating Organization: Universityof Central Florida (Department ofChemistry and Departments of Civil andEnvironmental Engineering)29

Environmental EngineeringEnhanced In Situ Zero-Valent MetalPermeable Treatment WallsContaminant PlumeConfining UnitReactionWallPermeable Treatment WallChlorinated solvents have beenwidely used by NASA andothers in the aerospace industryfor over three decades. Theyhave primarily been used asnonflammable degreasers anddryers for electronic parts. Historically,the disposal practices forspent chlorinated solvents includeddischarges to surfacewater and groundwater. It is,therefore, not surprising to findgroundwater solvent contaminationat 791 of the 1,300 NationalPriority List sites.Contaminant-FreeWaterTo date, the most commonlyused treatment method for thecleanup of chlorinated solventshas been the pump-and-treatmethod. With this method, thegroundwater is pumped to thesurface, and the contaminants areeither oxidized or removed withan air stripper. Although thepump-and-treat method wasoriginally thought to be a competentremediation tool, it hasshown itself to be most effectivein groundwater plume captureand containment. In general, itcan be said that the significantoperation and maintenance costsassociated with pump-and-treatsystems eliminate this remediationtechnique for large-scalecleanups.Within the last 5 years, asubstantial amount of researchfocused on the use of zero-valentmetals to catalytically enhancethe abiotic degradation of chlorinatedsolvents. Of the zerovalentmetals available and tested(iron, cobalt, zinc, and nickelprophyrins), iron is the mostattractive due to its low cost andavailability. With this technology,iron filings are mixed with sandand placed below the land surfaceand downgradient of thecontaminant source. Naturalgroundwater gradient transportsthe contaminated groundwaterthrough the iron/sand permeabletreatment wall. As the contaminantcomes into contact with theiron filings, catalytic degradationof the chlorinated species beginswith what appears to be thesimultaneous oxidation of iron bywater and the subsequent reductivedechlorination of the contaminant.In March 1998, a 40-foot-longand 4-foot-wide permeabletreatment wall was installed atLaunch Complex 34 at CapeCanaveral Air Station to a depthof 40 feet below land surface. Thedemonstration project tested anew construction technique thatuses deep-soil mixing with vibroinstallationas a method forgetting the reactive iron into the30

Research and Technology 1998subsurface. Preliminary analytical results indicate thatcontaminants such as cis-1,2 dichloride have droppedfrom an inlet concentration of greater than 13,000 µg/L toless than 60 µg/L, which is the Florida drinking waterstandard.Key accomplishments:• September 1997: Patent application submitted.• August 1997: Field-scale design completed.• March 1998: Construction completed.Key milestones:• Wall monitoring will continue over the next year withparticular attention on contaminant degradation andgroundwater geochemistry changes.• Ultrasound field testing will be conducted on the wallduring the next year (see the KSC Research and Technology1997 Annual Report), and a tracer study will beinitiated to examine groundwater flow patterns.Contact: J.W. Quinn (Jacqueline.Quinn-1@ksc.nasa.gov), JJ-D,(407) 867-4265Participating Organization: University of Central Florida(Departments of Civil and Environmental Engineering and theDepartment of Chemistry)Field Application of Deep Soil MixingField Application of Vibroinsulation31

Environmental EngineeringInstallation of a New Scrubber Liquor forthe Nitrogen Tetroxide Scrubbers ThatProduces a Commercial FertilizerNASA, in conjunction withDynacs Engineering Co.,Inc., and United Space Alliance, isinstalling a prototype of the newscrubber-liquor control systemthat converts nitrogen tetroxide(the hypergolic oxidizer) to afertilizer. The fertilizer producedby this process will be used onthe citrus groves at KSC. Thisproject is in Phase V of a fivephaseprogram to comply withExecutive Orders 12856 and12873, the Right-to-Know Laws,and the Recycling and WastePrevention Law. Hypergolicpropellants are used in spacecraftsuch as the Space Shuttle, TitanIV, Delta II, and other vehiclesand payloads launched at KSCand Cape Canaveral Air Station.Monomethylhydrazine (MMH),nitrogen tetroxide (N 2O 4or NTO),and hydrazine (N 2H 4or HZ) arethe main propellants of concern.Fueling and deservicing spacecraftconstitute the bulk of operationsin which environmentalemissions of nitrogen oxide (NO x)occur. The scrubber liquor wastegenerated by the oxidizer scrubbers(approximately 311,000pounds per year) is the secondlargest waste stream at KSC. Thedisposal cost for this oxidizerscrubber liquor waste is approximately$0.227 per pound or$70,600 a year.The new process will convertthe scrubber liquor to a highgradefertilizer (see the flowchart).The process reacts N 2O 4with hydrogen peroxide andpotassium hydroxide and producespotassium nitrate, a majoringredient in commercial fertilizers.This process avoids thegeneration of the hazardouswastes, which occurs whensodium hydroxide is used as thescrubber liquor. A patent applicationthat covers the process hasbeen filed with the U.S. Patentand Trademark Office.A feature of the new processis lower NO xemissions, since thenew scrubber is more efficient atcapturing nitrogen tetroxide thanthe current scrubber liquor. Forexample, when the two scrubberliquors were compared undersimilar test conditions, the emissionsfrom the new scrubberliquor were only 1 to 10 percentof the emissions from the currentscrubber liquor. A major effect oflower NO xemission will be toreduce the size of the area aroundthe oxidizer scrubbers that mustCurrent ProcessModified ProcessNitrogenTetroxideNitrogenTetroxideHydrogenPeroxideControlSystemOxidizerScrubberOxidizerScrubberSodiumHydroxideWaterPotassiumHydroxideByproducts are ahazardous waste thatmust be disposed ofSodium HydroxideSodium NitrateSodium NitriteNitric OxideWaterByproduct is a high-gradefertilizer that can besprayed on the groundPotassium NitrateProcess Converting Nitrogen Tetroxide Wastes to Potassium Nitrate, a Commercial Fertilizer32

Research and Technology 1998corrected during the current installation by changingthe point of addition of the reagents.In summary, this change in the scrubber liquorhas eliminated the second largest hazardous wastestream at KSC and produced a product that isapproved for application as fertilizer to the lawnsand citrus groves at KSC. This new scrubber liquoris a 15-weight-percent potassium nitrate solutionwith 0- to 1-weight-percent hydrogen peroxide anda pH of 7. The system is more efficient and lessexpensive than the current 25-weight-percentsodium hydroxide, when all factors including wastedisposal, fertilizer replacement, and handling ahazardous waste (the spent oxidizer scrubberliquor) are considered.Control Panel for the Oxidizer ScrubberControl Systembe cleared during operations, thus reducing theimpact of toxic hypergolic oxidizer emissions onadjacent operations.The new scrubber liquor and control system wastested with nitrogen dioxide (NO 2) concentrationsfrom low parts per million to pure vapor. To simulateoperations at KSC where aspirators are used tocapture NO 2vapor, up to 500 standard cubic feetper minute of gaseous nitrogen (GN 2) were addedto the NO 2stream. In addition, approximately 90pounds of oxidizer (vapor and liquid) were addedover a 1- to 9-minute period to the scrubber. Underall of these test conditions, the new scrubber-liquorsystem performed well and produced lower emissions.The only problem encountered during thefield tests, which will require slight modifications tothe scrubber, was due to inadequate mixing in thescrubber sump. These mixing problems are beingKey accomplishments:• Developed a method to eliminate the secondlargest waste stream at KSC (oxidizer scrubberliquorwaste).• Developed internal diagnostics that monitor theperformance of the control system.• Developed a production process for potassiumnitrate, a fertilizer currently purchased by KSCfor use on lawns and citrus groves.• Demonstrated that the process control system isrobust and can withstand field operations.• Demonstrated that the scrubber liquor is moreefficient with only 1 to 10 percent of the emissionsfound with the current 25-weight-percent sodiumhydroxide scrubber liquor.Contacts: R.C. Young (Rebecca.Young-1@ksc.nasa.gov) andD.E. Lueck, MM-G2, (407) 867-4439Participating Organization: Dynacs Engineering Co., Inc.(C.F. Parrish, C.J. Schwindt, T.R. Hodge, and P.H. Gamble)33

Environmental EngineeringLess Toxic Orbiter TPSRewaterproofing Agent StudyThe present orbiter ThermalProtection System (TPS)rewaterproofing agent,dimethylethoxysilane (DMES),performs exceptionally well inpreventing water absorption inceramic, silica-based materials.DMES reacts with the surface ofglass fibers in the tile or the fabricin blankets and deposits a film oforganic material that repels water.Although the tiles and blanketsare waterproofed when fabricated,reentry burns out the agentwhen temperatures reach 1,050degrees Fahrenheit or greater,thus requiring rewaterproofingafter each Shuttle mission. Theaction of waterproofing resultsfrom the bonding of dimethylsilanol, an unstable reactionintermediate, with hydroxyls onthe silica fiber surfaces. When atypical 6- by 6- by 2-inch Orbitertile is rewaterproofed, 2 cubiccentimeters (cm 3 ) of DMES isinjected with a needleless guninto a small hole in the center ofthe tile.The threshold limit value(TLV) for DMES is 0.5 part permillion (ppm). Some workerscomplained of throat irritationand light headedness after beingexposed to low-ppm levels ofDMES. Orbiter Processing Facility(OPF) ventilation systemmodifications were made tominimize this problem. In thecourse of applying DMES beforea launch, toxic vapor emissions tothe OPF high bay are significantenough to require the use ofprotective gear and a breathingapparatus. The bay must becleared of all nonessential personneland cannot be reopened forother vehicle work until theDMES vapors measure 0.5 ppm.Therefore, rewaterproofing mustbe performed on the third workshift and on weekends.A KSC Shuttle upgradesproject was initiated to find analternative, less toxic rewaterproofingagent to DMES butmaintain acceptable waterproofingperformance. Screening testswere performed with 2-inchLI-900 tile coupon cubes by injectingthem with 0.5 cm 3 ofwaterproofing agent. Also,material compatibility tests wereperformed with both types ofroom-temperature-vulcanizing(RTV) adhesives used in theorbiter TPS bonding process. Thecoupon screening tests uncoveredno waterproofing agent betterthan DMES. However, fivecarrier solvents [n-pentane; 2,3-dimethlybutane (DMB); 2,3-dimethyl pentane (DMP); acetone;and perfluorocyclobutane(PFCB)] were down-selected todilute the DMES (decrease itseffective toxicity) and to enhanceits dispersion throughout thesilica fibers in the orbiter TPS.Solutions of DMES in thesesolvents were injected into 6- by6- by 2-inch deep LI-900, reactioncuredglass (RCG) coated orbitertiles at various concentrations,and the resulting water uptakewas measured. Rewaterproofingresidue weight pickup was alsomeasured over a number ofcycles, and the results afterseveral injections showed insignificantaccumulative weightgains on the order of 0.2 percentor less. Another test series, tileoff-gassing detection, was performedto measure the concentrationand duration of the emittedvapors. RCG-coated tiles wereinjected with DMES/solventmixtures while the tiles were in aPlexiglas chamber. This procedurewas used to compare theemission and decay rate of 100-percent DMES versus DMES/solvent combinations using theFoxboro Miran 203 meter. AFourier Transform Infrared (FTIR)method (measures each constituentseparately), previously developedby the Toxic Vapor DetectionLaboratory for DMES carts,was used to measure the amountof solvent (ppm) detected whenthe Miran meter measured 0.5ppm. This data was compared tothe TLV of the solvent to determineif concentrations wereacceptable.Flexible insulation blanketswere also injected with the abovesolutions of DMES using a needlegun. After injection, severaldroplets of water were placed onthe surfaces of the blankets andobserved for absorption. Twotests each were performed with20-percent DMES solutions inDMP, DMB, and n-pentane. Twotests were also performed with10-percent DMES in PFCB. Allblanket rewaterproofing experimentswere successful in preventingwater droplets from enteringthe blanket surface.Overall, DMES solutions at 20percent in solvents performed34

Research and Technology 1998successfully in tiles (i.e., the water absorbed in tileswas less than 5 percent of the tile weight). Allsolvents were also compatible with both RTV’s.N-pentane was finally selected as the solvent forDMES due to its low toxicity and low cost, combinedwith its excellent repeatability with DMES. Intests comparing off-gassing data, a TLV equal to 0.5ppm was achieved 44 percent faster in a tile injectedwith 20/80 DMES/n-pentane versus 100-percentDMES (5.3 hours versus 9.5 hours) (see the figures).In conclusion, n-pentane is recommended as thecarrier solvent for DMES to decrease the overallagent toxicity. It has a low toxicity (TLV of 600ppm), low cost ($4 per gallon), and excellent repeatabilitywhen combined with DMES. The newrecommended rewaterproofing combination is a20/80 DMES/n-pentane mix. The benefits of usingthe recommended mix are: (1) a decrease of DMESvapors in the OPF; (2) a reduction in protectiveequipment safety criteria; (3) a decrease in the costto perform rewaterproofing due to reduced safetyrequirements, fan usage, and the cost of chemicals;(4) a chemical cost saving estimated at $147,200 peryear (based on the current 100-percent DMES versus20/80 DMES/n-pentane mix for eight flows peryear; (5) the number of clearances of the high baycould be minimized, thus reducing rewaterproofingflow impacts to long-term program manifest requirements;and (6) greater flexibility in therewaterproofing process.Contact: S.R. Cunningham (Suzanne.Cunningham-1@ksc.nasa.gov), AA-D, (407) 867-7089Participating Organizations: NASA-KSC (F. Jones, M.Cardinale, D. Lueck, and J. Branard); Comprehensive HealthServices, Inc. (J. Taffer); Boeing-Seattle (C. Newquist); DynacsEngineering Co., Inc. (R. Barile, N. Bardel, J. Curran,T. Hodge, P. Gamble, C. Mattson, B. Meneghelli, andC. Parrish); NASA-JSC (C. Schomburg); BNA-Downey(D. Bell and M. Gubbert); Ames-Elorett (J. Pallix); UnitedSpace Alliance (S. Nickell, G. Powers, R. Loeffler, andO. Torres); and KSC-BNA (R. Frittier)Tile Injection, 2 cm 3 20-Percent DMES in n-Pentane,50 Liters per Minute, M203Tile Injection, 2 cm 3 Pure DMES,50 Liters per Minute, M20335

Environmental EngineeringSupercritical Air-Powered EnvironmentalControl Unit for SCAPEKSC uses the Self-ContainedAtmospheric ProtectiveEnsemble (SCAPE) for the safeguardof personnel handlingrocket propellants. The existingconfiguration relies upon the useof a liquid-air-powered environmentalcontrol unit (ECU) thathas seen nearly 30 years of successfuloperation in support ofNASA and Air Force missions.The Category I configuration ofthis suit provides the user withtotally encapsulating protectionfor over 2 hours. However,several problems in the use ofliquid air have been identifiedand remain unsolved. Trainingand operational monitoring andconstraints have safely controlledthese problems to date.A new initiative has begun forthe development of an AdvancedProtective Suit (APS) that willmeet future mission supportneeds in an environment that isexpected to impose even lowertoxic threshold limit values forhuman exposures. Initial effortshave focused on the remediationof liquid air system problems.Specifically, these problems aredependent upon (1) an uprightdewar (storage vessel) attitude,(2) an unstable or nonhomogeneousliquid mix where theliquid nitrogen component boilsoff before the oxygen component,and (3) the determination ofdewar quantity throughout theservice life when the ECU is on aperson’s back and in motion,which often is in an unusualattitude.A feasibility study of thestorage and use of air in asupercritical phase has beensuccessfully conducted in theBiomedical Laboratory at KSC.This development was an extensionof technology gained in aSmall Business Innovation Researchproject conducted byAerospace Design and Development,Inc., where a supercriticalair, positive pressure demand,self-contained breathing apparatuswas designed. The SCAPEECU is a constant-flow systemthat supports respiration andcooling of the user. The new ECUstores 6.5 pounds of supercriticalair in a high-efficiency dewar andprovides the air, after conditioning,to the suit air distributionmanifold. The prototype designwill be further modified to employa more effective liquidcooledgarment in place of aircooling. Problems with attitudesensitivity, stability of the gas,and quantity measure have beensolved in this relatively lowerpressure, cryogenic, gaseoussystem.Contacts: D.F. Doerr (Don.Doerr-1@ksc.nasa.gov), JJ-3, (407) 867-3152;and M.B. Brown, FF-D2-D, (407) 867-718636

Research and Technology 1998AdvancedSoftwareThe goal of the Advanced Softwareprogram at the John F. KennedySpace Center (KSC) is to investigateand develop cutting-edge advanced softwaretechnologies in support of launch andground processing functions. New softwaretechnologies are being developed toimprove capabilities and reduce operationsand maintenance costs for present andfuture vehicles, payloads, and launchsystems.To meet the challenge of becoming moreefficient in all aspects of KSC work, advancedsoftware technologies are beingdeveloped from the expanding technologicalbase; and these technologies are beingused to improve performance, save time,and increase productivity. This year’sAdvanced Software program employs abroad range of disciplines and technologies,including programs that process vastquantities of data and make the data availablefor Operation’s use through tools(such as the Internet), model-based reasoningsystems to autonomously managecomplex chemical processing systems, andadvanced mathematical techniques thatenhance capabilities for imaging and waveanalysis.37

Advanced SoftwareMars ISPP Autonomous ControllerTrans-MarsSolar ArrayHeatShroudKSC’s Roadmap to the Futureplaces an emphasis onNASA’s efforts to develop thetechnologies necessary to send amanned mission to Mars. A keyelement of NASA’s strategy tosend a manned mission to Mars isthe utilization of resourcespresent in the Martian environment.This element is known asIn Situ Resource Utilization(ISRU). One component of ISRUis the production of fuel andoxidizer for the Crew AscentVehicle. This is called In SituPropellant Production (ISPP).Communication lags betweenthe Earth and Mars make itimpractical to control the ISPPplant directly from Earth. Therefore,autonomous control softwareis necessary to operate theISPP plant with little or no helpfrom ground controllers. Sincethe plant has to operate for over ayear, the control software must beadaptive. It must be able tohandle component failures aswell as degradation of the chemicalprocesses. Because of thebroad applicability of autonomouscontrol, this project willhelp increase the body of knowledgefor all control system needs— whether targeted at mannedmissions to Mars or groundlaunch systems for the Shuttle.An important aspect of thisproject is the partnerships withother centers that make it possible.Johnson Space Center (JSC)is the lead center for the developmentof ISRU technologies, butthey are partnering with othercenters to capitalize on their areasof expertise. For the ISPP project,both Ames Research Center(ARC) and KSC have experiencewith artificial intelligence (AI)software for autonomous control.For the ISPP effort, KSC willcreate the AI program for autonomouscontrol using a languagecreated by ARC. As the projectprogresses, KSC will help ARCextend the capabilities of theirlanguage to incorporate moredynamic process modelingcapabilities needed to fullyimplement the ISPP controller.HeatShieldPropellantPlant3-Descent EnginesMars ISRU Sample ReturnMars Entry VehiclePropellantLiquifaction Unit3-Lander LegSystemThe primary objective for theMars ISPP autonomous controllerproject is to develop autonomouscontrol software that will operatea prototype ISPP plant constructedat JSC. However, JSC isstill experimenting with severaltechniques for ISPP, so immediatepursuit of this objective is premature.In order to elevate AI38

Research and Technology 1998technology to the necessaryreadiness level, a simplifiedautonomous control packageusing the ARC-developed languagewill be created to operate asimulated ISPP plant. This willfacilitate development of softwaremodules to communicate withthe user and interface with thehardware. It will also helpidentify enhancements the ARClanguage needed to handlequantitative modeling issuespresented by ISPP.As these enhancement needsare identified, KSC will workwith ARC to develop solutions.Once the enhancements arecompleted, KSC will use thisenhanced language to create acomprehensive autonomouscontroller for the ISPP simulation.When the JSC ISPP prototype iscompleted, KSC will deliver theautonomous controller softwareto JSC, where it will be integratedwith their adjustable autonomytest bed. KSC will make all thenecessary modifications to adaptthe autonomous controller to theJSC prototype hardware.Key accomplishment:• 1998: Demonstration of thecircuit breaker and powerdistribution control systemusing model-based reasoning.Key milestones:• 1999: Demonstration of apreliminary ISPP monitoringand control system. Continuethe development of ISPPmonitoring capabilities. Expandthe functionality toinclude quantitative andsemiqualitative diagnostic andcontrol functions.Contact: W.E. Larson (William.Larson-1@ksc.nasa.gov), MM-G1, (407) 867-674539

Advanced SoftwareJView Internet Display of ShuttleReal-Time Data Using JavaThe rapid growth of Internet access to informationsince 1995 has resulted in a significantparadigm shift in how information is accessed andthe resulting expectations of users concerninginformation availability and ease of access. Duringthe past 4 years, however, the type of informationaccessed on the Web has primarily been static innature. The recent availability of Java has enabled anew class of applications that contains dynamiccontent and real-time data sources over the Internet.The use of Java for display of real-time Shuttle dataas presented here represents a demonstration ofhow existing applications at KSC could be implementedusing the Internet paradigm.The current display of real-time Shuttle datainvolves a centralized server that receives data fromthe common data buffer and sends it to Intelprocessor PC clients who display it on predefinedscreens. PC clients use MS-DOS and characterbasedgraphics with close ties to specific hardware,operating systems, network interfaces, etc. Thisimplementation has no inherent security or abilityto work globally, and the PC becomes dedicated tothe display of data.Using Java presents an ideal approach sincemuch of the effort in establishing a client/serverconnection across a local or wide area network isalready provided. Java supports implementingsolutions as both applications and applets. Theapplet was used for the client-side display of Shuttlescreens. The advantages of a Java-based solutionare geographic independence; shorter developmentand training; write once, run anywhere applications;security; ease of administration; and multipleShuttle displays.The initial goal for the Internet Display ofShuttle Real-Time Data Using Java project was todemonstrate the feasibility of using Java and acommercial off-the-shelf (COTS) Web browser todisplay real-time Space Shuttle data, equivalent tothe current application called PCGOAL. This wassuccessfully demonstrated in the Automated andIntelligent Systems Computer Laboratory, wheremultiple computers of differing configurationsdisplayed the following data: (1) hardware (IntelX86, Sun SPARC, and Motorola POWER PC), (2)operating system (Solaris, SunOS, WindowsNT,Windows95/98, and Macintosh Finder), and (3)Web browser (Netscape Navigator, Version 4.0+;and Internet Explorer, Version 4.0+).In addition to demonstrating a single Webbrowser/JView client display on each of sevensystems simultaneously, a test of nine different Webbrowser/JView client displays on a singleWindowsNT system was possible. The best displayresults were achieved using version 4.0 of NetscapeNavigator and Internet Explorer, which contain ajust-in-time compiler for Java, greatly improvingdisplay performance by at least an order of magnitude.The current phase involves taking the proof-ofconceptwork completed earlier and applying thetechnology to solve actual monitoring requirementsat KSC and other NASA centers. In conjunctionwith this implementation, additional system designand testing will be accomplished in the areas of(1) tuning the applet (client) and application(server) for maximum performance; (2) establishingrobust extensible class libraries of reusable softwarecomponents, applicable for present and futureprojects; (3) analyzing network bandwidth utilizationto support the maximum number of clients; (4)providing direct connections to data sources, bothreal-time and historical; (5) developing graphicaluser interfaces with increased display options andresizable screens; (6) developing advanced plottingcapabilities using Java “swing” technology tomaximize extensibility; and (7) extensive systemlevel testing and certification.The viability of using Java, a relatively newlanguage/runtime environment, in conjunctionwith a COTS Web browser to rapidly develop anddeploy process monitoring and control applications,has been demonstrated. This new technology hasthe potential of significantly reducing the time andcost of developing and maintaining applications,given the flexibility to write the application onceand run it anywhere. Use of COTS systems and aWeb browser minimizes the cost, configuration, andtraining issues associated with deployment of new40

Research and Technology 1998applications. This type of solution has great potentialapplicability at KSC, other NASA centers, andindustry technology transfer in the areas of: (1)training using live or simulated data sources, (2)real-time monitoring of live Space Shuttle data (orany type of data source), (3) expert/advisorysystems for predictive analysis, and (4) historicalreview for postmission data analysis and review.Contact: K.C. Ballard (Kim.Ballard-1@ksc.nasa.gov), MM-G3, (407) 867-1720Participating Organizations: Dynacs Engineering Co., Inc.(J.M. Dockendorf, C.H. Goodrich, S.R. Beltz, and M.S. Long),Florida Institute of Technology (Dr. R. Stansifer), PrincetonUniversity (K. Gillett), and Duke University (W. Riddle)41

Advanced SoftwareAutomation of OMI S9002 forOrbiter ProcessingThe term S9002 refers to theoperations and maintenanceinstruction (OMI) for the PosttestData Review by responsibleengineers of sensor data collectedduring the certain critical processingof orbiters from the time oflanding up to and includinglaunch. OMI S9002 includes anumber of subordinate OMI’s.One is S0007, the OMI for orbiterlaunch, which includes theproduction of roughly 2,500sensor readings (data products)that require review by engineersresponsible for each of theorbiter’s subsystems and supportingsubsystems (e.g., mainengines, hazardous gas systems,auxiliary power units, etc.).Data products are hard-copyprintouts of charts, plots, graphs,or listings for specific sets ofperiodic sensor readings, usuallyspecified for a predeterminedtimespan, that include a startevent and stop event. Some dataproducts are also run on demandat the request of a responsiblesubsystem engineer (typically inthe firing room) who specifieswhich data product to produceand provides specific start andstop times. These data productsare termed “will calls.”The present S0007 processincludes the following steps.First, Data Review Room (DRR)personnel physically monitor thelaunch process for specific dataproduct start and stop events tooccur. Next, after certain stopevents occur (which may behours or days following a stopevent), DRR personnel log intothe central data system (CDS),request a specific data product tobe run, and specify the printer orplotter for the hard copy printout.The hard copy is either picked upor hand carried to the engineer(will calls). The responsibleengineer then reviews the physicaldata product, analyzes thedata for potential problems, anddetermines the health of thesubsystem (analysis of largelistings may take hours). Theengineer then returns to the DRRto buy off the data product forwhich he/she is responsible (thiscan be 1 to 300 data products persubsystem).The original goals of theS9002 automation project were(1) to automate the generation ofgreater than 80 percent of thedata products for OMI S0007,with emphasis on hazardous gas;(2) to enable the display, to review,and to sign off those dataproducts by responsible engineersfrom their desktop computersusing the World Wide Web;and (3) to investigate the use ofavailable commercial off-the-shelfproducts and/or rule-basedtechnologies that could assist theresponsible engineers with theanalysis of the data products.The S9002 database wasmodeled, designed, and implementedusing a full-functionRDBMS (Oracle 7) and a modernWeb server. Code was written toautomatically load the databasefrom all available legacy systemsources to include DRR Dbase IV,CDS formatted files, CDS transactionfiles, and CDS FD files.Listeners and agents were integratedinto the database server toenable a transparent interface toall other S9002 subsystems,whether local or remote, andsupport many language interfaces.An event monitor was designedand implemented usingthe Java language to monitor theoccurrence of start and stopevents and was interfaced to boththe Shuttle Data Center (SDC)and S9002 databases. An applicationserver module was alsodeveloped using the Java language,which communicates withthe event monitor, SDC, theanalysis module, and S9002database to handle the schedulingand control of data productcreation, transfer to the databaseserver, and the triggering of dataproduct analysis. In parallel, theprograms that actually producethe data products (DAP’s andCAP’s) were moved from theCDS to the SDC and modified toenable production of electronicfiles. These programs also underwentsignificant coding modificationto enforce standardization ofinputs, options, and functionality.Tests where then performed tomake sure the new S9002 applicationserver module could successfullycall and execute these SDCresident programs.In another effort, an analysismodule was being investigatedand contrived. It was decided tocreate a rule-based applicationmodule that would perform the42

Research and Technology 1998S9002 automation project to datehave exceeded the original requirements.same steps as an engineer whenanalyzing a large collection ofhazardous gas sensor data. Acomplete set of rules was establishedfor several of the largestdata sets by interviewing theengineers and documenting theirthought processes. These ruleswere then organized into a Javaapplication class, and methodswere written to enable reducingthe analysis to a single pageoutput that describes if therewere any anomalies found. Ifthere were anomalies, a briefexplanation of each would beincluded along with violatedparametrics.Being developed in parallelwith the other modules was theuser interface. This module wasscoped to run on platformindependentdesktop computers,with the only requirement beingTop-Level Menu Page for Administratorsthat the platform support acommercially available Webbrowser. Two paths were takenin the development of the GUI.One implementation proposedthe use of uploadable JavaApplets for all menus andscreens, which yielded compatibilityproblems with browsers,slow loading, and difficulties incoding and maintenance. Theother implementation involvedthe use of the PL/SQL languagefor the dynamic creation ofHypertext Markup Language(HTML) sent to/from the clientplatform, which yielded ahighly responsive, easy to codeand use interface with dynamicscreen sizing. While bothsolutions could eventually bemade to work, the PL/SQLsolution was chosen for implementationof the S9002 automationat this time. Results of theAs a result of this project,greater than 95 percent of dataproducts for S0007 (orbiterlaunch) are run fully automaticallyand are typically availablefor viewing within 30 secondsafter stop events occur. The S9002database and application softwaresupports all S9002 OMI’s(approximately 5,300 data products).Engineers can run any dataproduct at any time by specifyingboth start and stop times (willcalls) and can create custom dataproducts at will and execute themimmediately. Several SpaceTransportation System flows canbe run simultaneously withoutconflicts. The rule-based analysisof large volumes of data forhazardous gas has proven to bevery efficient and has identifiedin near real time many interestinganomalies (gas leaks, powersupply outages, etc.) hours beforebeing discovered by the responsibleengineers using manualmethods. Responsible engineersnow have a tool to monitorsubsystem health, review discoveredanomalies, and electronicallysign off completed data productswithout leaving their desks.Contact: W.C. Jones (William.Jones-3@ksc.nasa.gov), MM-G3, (407) 867-4181Participating Organizations: DynacsEngineering Co., Inc. (W. Spiker, II; J.M.Dockendorf; and J. Zambrano), UnitedSpace Alliance (W.S. Bayles), andBoeing (D.J. Cox)43

Advanced SoftwareWeb-Based Work Tracking SystemsThe Logistics OperationsDirectorate’s Materials ScienceDivision (MSD) has a new softwaresystem running in real timeon the World Wide Web. Thissystem is named the Work TrackingSystem (WTS) and it demonstratesthe integration of commonWeb browsers with a commerciallyavailable relational databasemanagement system tocreate a single, user-friendlymeans of controlling work flow.The MSD laboratories wereestablished during the Gemini erato provide quick laboratorysupport to vehicle and facilityoperations at KSC. The MSD wasGovernment and contractoroperated but was converted to a100-percent Civil Service operationin 1968 so unbiased investigationscould be provided.Prior to this new application,each group in the MSD kept aseparate report log containingunique fields, such as investigatorname, date started, date completed,and report number. TheWTS offers a single means ofmaintaining the report log andtracking the work flow, resultingin a much more efficient operationfor both laboratory investigatorsand their customers. TheWTS also aids the MSD in theireffort to become ISO 9000 compliant.The benefits and features ofthe WTS are many. The system ishardware and software independenton the server side – practicallyall server manufacturers andoperating systems can run it. Onthe client side, practically alldesktop computers, includingAdministrators Page44

Research and Technology 1998Macintosh, PC, and UNIX workstations, can use WTS with a Webbrowser.WTS offers a full-function,relational database managementsystem (RDBMS). Featuresinclude referential integritychecking, security, transactionlogging, and a distributed database.The RDBMS selected forthe WTS implementation isOracle because of its wide usageat KSC.The Web pages are dynamicallycreated in real time based onuser inputs using ProceduralLanguage/Structured QueryLanguage (PL/SQL) that is storedin the database itself. Browsertables are also produced dynamically.The use of PL/SQL forWTS implementation results infast system response time.The WTS’s current serverconfiguration is a Sun Sparc II,running Solaris 2.5.1 (UNIX),Oracle Enterprise RDBMS, andWeb server software. The clientneeds only a PC, Mac, or UNIXwork station and a Web browser(such as Netscape or InternetExplorer) to access the system.Similar systems were alsodeveloped and implemented atKSC, including the KSC Correctiveand Preventive Action Systemtracking audit, nonconformity,and opportunity for improvementstatuses. Othersystems still in developmentinclude the KSC CenterwideAwards system that will track allNASA awards and the awardbudget. Other WTS demonstrablefeatures include:• Automatic e-mail to customerswith status changes, such asjob on hold, job complete• Automatic notification to MSDpersonnel for new jobs andstatus updates• Ad hoc reporting• Security and access controlwith password and firewall• Automatic file transfer• Transaction logging• Electronic signatures• Add and display job documentsincluding pictures andreports• Job splitting• Equipment calibration tracking• Part/material trackingContacts: W.C. Jones (William.Jones-3@ksc.nasa.gov), MM-G3, (407) 867-4181; and K.C. Ballard, MM-G3, (407)867-1720Participating Organizations: LO-G4-M(S. Murray) and Dynacs EngineeringCo., Inc. (N. Tuttle and W. Spiker)45/46

Research and Technology 1998AtmosphericScienceThe Atmospheric Sciences Technologyprogram at the John F.Kennedy Space Center (KSC)addresses the impacts of weather onground, launch, and landing processingwith a view to increasing safety of personnel,protecting resources, and reducinglost work time by improving detection,analysis, and prediction of weatherevents and protection from weatherevents. Many of the weather impacts areof a specialized nature, differing fromthose felt by the public and even aircraftoperations, and require studies anddevelopment that cross the lines ofconventional scientific disciplines.Weather events focused upon by theprogram include lightning and cloudelectrification, convective cloud growth,atmospheric surface and planetaryboundary layer circulations and processes,wind shear effects, severe weatherphenomena, rain, wind, and fog.47

Atmospheric ScienceHurricane Wind SensorThe objective of this project is todevelop a low-cost, highspeedwind sensor and a selfcontaineddata acquisition systemfor in situ measurement of windsfrom hurricanes and tornadoes to300 miles per hour. Scientists atthe National Oceanic and AtmosphericAdministration (NOAA)indicated a need for such asystem and have formally requestedKSC to undertake thedevelopment. When hurricaneAndrew struck South Florida in1992, there was no reliable landbased,maximum wind speedmeasurement. All known sensorsin Andrew’s path of maximumwind were destroyed, presumablyin winds short of maxima.The controversy continues todayFigure 1. New-Generation Wind Sensor Incorporates Strain GageTechnology for Compact Design and High-Speed Performancewith some scientists estimatingAndrew’s gusts at greater than200 miles per hour. High windspeed information is needed atKSC to allow engineering assessmentand recertification of facilities,ground support equipment,and flight hardware should anextreme wind event occur.The high wind speed sensor(see figure 1) at KSC uses twodifferent principles of physics toprovide two independent measurementsof wind speed: (1) theaerodynamic force imparted to alow-profile, rigidly mountedcylindrical rod and (2) the vibratingfrequency of the rod asvortices are shed from the cylindricalsurface. A common set ofstrain gages is used for bothmeasurements. The force measurementis proportional to thesquare of the wind speed. Since itis a vector quantity, it can also beused to infer wind direction. Thevortex shedding frequency is ascalar quantity and is linearlyproportional to wind speed. Thedata system is battery operated,designed for unattended operation,and hermetically sealed towithstand driving rain and stormsurge flooding that is typicallyassociated with landfall hurricanes.The system will automaticallyacquire and store at least 72hours of sustained and peakwindinformation for poststormevent analysis.A prototype data acquisitionsystem was designed and fabricated.Three generations ofprototype sensors were designedand tested with each showing48

Research and Technology 1998Figure 2. Raw Data Plot of Strain Gage (SG) Anemometer Versus Turbine Air Speed Sensor(Vehicle Test at the SLF)significant improvement over its predecessor. Thefunctional characteristics revealed during preliminarywind tunnel testing of the first design wereused to refine the subsequent designs. The latterdesigns were tested to 120 miles per hour on a roadvehicle at the Shuttle Landing Facility (SLF) (seefigure 2). Wind speed values inferred from staticstrain (force) measurements agree well with thoseobtained from a co-located turbine air speed sensor.The frequency components of the sensor output, asrelated to the probe’s mechanical resonance andvortex shedding vibration, have not been fullyanalyzed but preliminary findings show promisethat independent wind speed measurements areextractable from the frequency spectra.Key accomplishments:• Designed and fabricated a prototype data acquisitionsystem printed circuit board.• Designed, fabricated, and laboratory tested threegenerations of prototype wind sensors.• Proved that force measurement is a viablemethod of inferring wind speed and direction toat least 120 miles per hour (midcategory 3 hurricane).• Initiated an investigation of vortex sheddingfrequency as a function of wind speed.Key milestones:• Deployment of sensor during 1999 Atlantichurricane season.• Final design and completion of sensor by October1999.Contact: J.A. Zysko (Jan.Zysko-1@ksc.nasa.gov), MM-G2-A,(407) 867-6532Participating Organization: Dynacs Engineering Co., Inc.49

Atmospheric ScienceSingle-Station Accurate Location of Lightning StrikesThe objective of this project is todesign an accurate singlestationlightning location systemto aid in the detection of lightningstrikes within the launch padperimeter. This project is anupgrade to the lightning locationsystem first conceived in 1997.Existing lightning location systemsat KSC provide coverage ofa wide area extending over a 30-mile radius but have an accuracyon the order of about 500 meterswithin the KSC area. Thesesystems cannot be used to determine,for instance, whether alightning strike occurred inside oroutside the perimeter of thelaunch pads. Since electronicequipment can be damaged bythe effects of nearby lightningstrikes, the accurate knowledge ofthe striking point is important todetermine which equipment orsystem needs to be retestedfollowing a lightning strike.The fast-varying electriccurrents associated with lightningstrikes generate large electric fieldvariations. The electric fieldwaveform propagates at thespeed of light in a radial directionfrom the striking point. Thesudden heating of the air causedby the large currents associatedwith the lightning dischargeproduces a sudden expansion ofthe air near the lightning channel.This results in a sonic wave(thunder) that initially, for thefirst few meters, propagates at asupersonic speed and laterpropagates at a sonic speed. Foran observer located away fromthe striking point, the electricfield waveform arrives earliersince it travels at a speed of300,000,000 meters per second(m/s), while the sonic wavetravels at about 320 m/s. Theobserver can determine thedistance to the striking point bymeasuring the time between thearrival of the electric field waveformand the arrival of the sonicwave.The improved lightninglocation system consists of anelectric field sensor and five sonic(thunder) recorders. Four ofthese sonic sensors are located inthe perimeter of a 1- or 2-meterradiuscircle, 90 degrees apartfrom each other, with the electricfield sensor placed in the centerof the circle. The fifth sonicsensor is located 1 or 2 metersabove the plane formed by thefour sensors. Following a lightningstrike, the sonic wavearrives at each sensor withinmilliseconds of each other, sincethe distance to the striking pointis slightly different for each sonicsensor. Based on the differencesin the time of arrival of the sonicwave at each sensor, a set ofequations can be solved to determinethe angle of arrival of thesonic waveform. The differencesin the time of arrival can beprecisely measured, to better than10 microseconds, by performingreal-time digital cross-correlationsamong the signals receivedby the five sensors. The distanceto the lightning strike is determinedby the time elapsed fromthe detection of the electric fieldto the detection of the thunder50

Research and Technology 1998signal, since the thunder propagates at a known speed ofabout 320 m/s.Key accomplishments:• Designed and prototyped the electric field sensor, thesonic sensors, and the microprocessor-based controller.• Developed an algorithm to combine the informationreceived from a network of sensors to determine theangle of arrival of the thunder signal.Key milestones:• Conduct field tests at the launch pads.• Evaluate the performance of the system and refine thealgorithms if needed.Contact: C.M. Ihlefeld (Curtis.Ihlefeld-1@ksc.nasa.gov), MM-G2-A,(407) 867-6747Participating Organization: Dynacs Engineering Co., Inc.(P.J. Medelius, J.D Taylor, and J.J. Henderson)51/52

Research and Technology 1998MaterialsScienceThe Materials Science Technologyprogram at the John F. KennedySpace Center (KSC) supportsadvanced technologies directed towardimproving launch site safety, operability,and maintainability. The program includesapplication materials engineering,materials testing, chemistry, and otherscience disciplines. The near-term programfocuses on Shuttle ground processingimprovement by providing materialsand coatings that afford better corrosioncontrol, materials with better hazardoussystems compatibility, and improvedtesting methods and instrumentation.The long-term program will (1) investigatematerials technology that can beused to develop new launch and processingfacilities for future vehicles andpayloads, (2) reduce the cost of maintenance,(3) provide higher safety andreliability, and (4) provide more environmentallyfriendly systems.53

Materials ScienceStudy of Electrostatic Charging and Discharging ofMaterials in a Simulated Martian EnvironmentThe Materials Science Laboratoryhas been studying andtesting electrostatics of materialsfor the past 25 years. Electrostatics(or triboelectricity) is concernedwith the tendency ofmaterials to build up and hold apotentially dangerous staticcharge. Research efforts forelectrostatic testing of materialsunder vacuum or in extraterrestrialenvironments do not exist.The goal of this project is to testthe materials under vacuum thatwill be used for future Marsmissions and to simulate Martianconditions to determine theirtriboelectric properties. Resultsfrom this testing will guide theselection of materials not only forMartian exploration but for otherspace exploration.Vacuum ChamberThe potential issues regardingtriboelectric properties of materialshave become significant withthe recent Pathfinder mission toMars. The surface of Mars mainlyconsists of iron oxides andlarge amounts of very fine materialsthat are similar to talcumpowder. Particles of this sizepose special problems becausethey have increased mobility andcan easily become attracted tooppositely charged surfaces fromgreater distances. The Martianenvironment is windy (30 metersper second at peak velocity) withperiods of low temperatures andextremely dry conditions. Thisprovides ideal conditions necessaryto generate triboelectriccharging.The project was initiated inMarch 1998. A vacuum chamber40 inches in diameter by 60 inchesin length was purchased in April1998 and is currently beingequipped with controls to simulatethe Martian environment. Arobotic triboelectric tester is beingdesigned to operate remotely inthe vacuum chamber. A Martianregolith soil simulant was obtainedfrom Johnson Space Center(JSC) for researching the possibleelectrostatic charging of Martiansands. The soil simulant isvolcanic ash from the Pu’u Nenecinder cone on the island ofHawaii. Consequently, a prototypewas designed and built forthe soil simulant delivery system.The prototype will simulate theMartian atmospheric movementof soil to determine if there is54

Research and Technology 1998electrostatic charge generation onthe selected materials. Theresearch efforts in the upcomingyear will focus on the vacuumchamber, procuring the materialsselected for the future Marsmissions, and testing the simulantsoil and materials at ambientconditions as well as in thesimulated Martian environment.Key accomplishments:• Procured a vacuum chamber.• Obtained and analyzed theMartian regolith soil simulant.• Built and tested the first proofof-conceptprototype for a soilsimulant delivery system.• Initiated the design for therobotic triboelectric tester.• Mars electrostatic dischargeplan presented and acceptedby JSC in situ resource utilizationleads.• Collaborated with LewisResearch Center, who is developingthe methodology toremove dust from photovoltaiccell surfaces.Key milestones:• February 1999: Completemodifications to the vacuumchamber.• September 1999: Complete thetesting and calibration of theMartian Environmental Compatibilityassessment electrometerattached to the Marsrobotic mission for the JetPropulsion Laboratory.• October 1999: Determine thetriboelectric characteristics ofthe simulant soil at ambientconditions and in the simulatedMartian environment.Complete the fabrication andtesting of the robotic triboelectrictester.• September 2000: Determinethe triboelectric characteristicsof the selected materials undervacuum conditions and in thesimulated Martian environment.• May 2001: Submit the contributionto the electrostaticsexperiment package on the2003 Mars robotic mission.Identify and evaluate methodsto reduce charge buildup onMars Rover mission vehicles.Contact: H.S. Kim, Ph.D. (Hae.Kim-1@ksc.nasa.gov), LO-G3-C, (407) 867-3911Participating Organizations: LO-G3-C(D. Jackson), LO-G3-T (A. Finchum, Dr.R. Gompf, Dr. R. Lee, D. Lewis,M. Parenti, and N. Salvail), LO-G4-E(J. Bayliss and J. Rauwerdink), LO-G4-M (P. Richiuso), and Sweet BriarCollege (Dr. C. Calle)55

Materials ScienceInvestigation of Water Soluble Polyaniline as a Replacement forChromate Coatings on Aluminum AlloysResearch has been ongoing forover 20 years at the KSCMaterials Science Laboratory tofind coating materials to protectlaunch site structures and equipmentfrom the extremely corrosiveconditions present at thelaunch complexes. The combinationof proximity to the AtlanticOcean and acidic combustionproducts from solid rocket boostersduring launch results incorrosive stresses unique to KSC.In the mid-1980’s, researchers atthe Materials Science Laboratorybecame interested in polyanilines(PANI’s) as protective coatingsfor metallic surfaces.Several proprietary PANIbasedcoatings were tested at KSCas possible coatings for theprotection of steel from corrosion.Exposure of PANI-coated steelpanels at the KSC beach corrosiontest site and evaluation by electrochemicalimpedance spectroscopy(EIS) led to the conclusion thatthe PANI-based coatings are notsuitable as corrosion inhibitors ofstainless steel.The PANI-based coatingspreviously tested for the corrosionprotection of steel were notwater soluble. Water-solublePANI’s have been synthesizedrecently. Water solubility hasfavorable economic and environmentaladvantages in terms ofease of processing and of reducedtoxicity. Interest in new protectivecoatings for aluminum alloyshas been motivated by concernfor improved protection and theenvironment. The availability ofthe water-soluble PANI coatingslead to the idea of testing them aspossible replacements for chromatecoatings on aluminumalloys.In the present investigation,EIS was used to investigate thecorrosion-inhibiting properties ofa PANI-based coating on aluminumalloys under immersion inaerated 3.55-percent sodiumchloride. The coating was preparedby mixing a water-solublelignosulfonic acid dopedpolyaniline with a high solidsmethoxymethylated melamineresin in a 1:2 ratio. The alloysused were aluminum 2024, 6061,and 7075.Corrosion potential and EISmeasurements were gathered onthe test specimens over a 1-weekimmersion period each. Nyquistas well as Bode plots of the datawere obtained. The PANI-coatedalloys showed large fluctuationsin the corrosion potential duringthe first 24 hours of immersionthat later subsided and approacheda steadier change. TheEIS spectra of the PANI-coatedalloys were characterized by animpedance that is higher than theimpedance of the bare alloy.Changes in the EIS spectra weresimilar for PANI-coated aluminumalloys 2024 and 7075. Therewas a decrease in the rate ofcorrosion of these alloys duringthe first 24 hours of immersionfollowed by an increase. The rateof corrosion of PANI-coatedaluminum 6061 did not show theinitial decrease. The rate ofcorrosion of bare aluminum 2024decreased with immersion time.The low-frequency impedance (at0.05 hertz), Z lf, for the PANIcoatedalloys decreased withimmersion time. Visible signs ofcoating failure (in the form ofblisters) developed on aluminumalloys 2024 and 7075.Key accomplishments:• Water-soluble polyaniline wassynthesized.• A coating using water-solublepolyaniline was formulated.• Aluminum alloy panels withwater-soluble polyanilinecoating were prepared.• EIS testing of polyanilinecoatedaluminum alloy panelswas conducted.Key milestones:• Conduct tests of polyanilinecoatedaluminum alloys includingexposure at the KSCbeach corrosion test site andEIS measurements.• Perform analysis of the metalsubstrate using metalography.Contact: C.J. Bryan (Coleman.Bryan-1@ksc.nasa.gov), LO-G3-C, (407) 867-4614Participating Organizations: Randolph-Macon Woman’s College (Dr. L. Calle),LO-G4-M (L.G. MacDowell), andUniversity of Arkansas at Little Rock(Dr. T. Viswanathan)56

Research and Technology 1998Qualified Materials Listings forPlastic Films and Adhesive TapesAneed existed in 1990 at KSCfor information that couldreadily be available to engineerswho must make the choice ofwhich plastic film to use for aspecific application. Plastic filmsare commonly used to wrap flighthardware for ground processing,to package small componentsprior to delivery, or to providelimited barrier protection fromminor (leaking) amounts of liquidrocket propellant. The adhesivetapes used to assemble andsecure these plastic films mustequally be readily available to theengineer. The need for qualifiedfilms and tapes was also drivenby safety requirements that areunique to KSC (which include areasonable resistance to flammability,a material that is minimalas an electrostatic generator, andtotal ignition resistance to hyper-golic rocket propellants). Whilevendor literature could be used todetermine the mechanical propertiesof a film or tape, there was nosuitable industry data that couldaddress the above safety concernswhich would be acceptable toKSC.In order to tailor the programfor KSC, only those materialsrequested by KSC contractorswere initially evaluated. Othermaterials that were submitted byother NASA centers or by vendorswho wished to be includedin the listings were evaluatedwhen time and resources wereavailable. An electronic databaseof test results was subsequentlyestablished from which thelistings could be created. The testmethods used to produce thesetest results were:1. Flammability testing perNASA-STD-60012. Electrostatic testing per KSC/MMA-1985-793. Hypergolic ignition penetrationtesting per KSC/MTB-175-88Each film or tape was subsequentlycategorized based on itsability to meet some or all safetyrequirements. This would enablethe user to quickly access candidatematerials once the operationalneeds are determined. Amaterial must at least pass theflammability acceptance criteriabefore it can be included in thequalified listings. These listingsare updated on a quarterly basis.Contacts: N.P. Salvail (Napoleon.Salvail-1@ksc.nasa.gov) and R.J.Frankfort, LO-G3-T, (407) 867-140357

Materials ScienceDetermination of Sodium in Colloidal SilicaLudox AS-30, a product ofDuPont, is a colloidal silicasolution containing sodium thatis used in many aspects of theorbiter’s Thermal ProtectionSystems. Ludox is incorporatedinto thermal tile production andrepair and flexible insulationblanket coatings and serves as thebasis for adhesives. The amountof sodium present in the colloidalsilica solution used for thesepurposes has a direct effect onthe level of crystallinity observeddue to the formation of cristobalite.The presence of cristobaliteis detrimental to the performanceof materials due to itstendency to exfoliate or flake.The Materials Science DivisionTest Branch has been involvedwith the development of a reliableand expedient method fordetermination of the level ofsodium present in such silicacolloids.Several methods have beenattempted in devising a quantitativeanalysis for sodium in silicacolloids. Initially, ASTM MethodC575-81, inductively coupledargon plasma (ICAP), and ionchromatography were used.None of these procedures gavereliable or reproducible results.Following consultation withchemists at DuPont, a modifiedprocedure using ICAP wasdeveloped. This method involvesdigestion of the colloidal dispersionusing hydrofluoric acid andnitric acid. After addition of theacids, the samples are heatedinside a CEM MDS 81D microwaveuntil complete dissolutionoccurs. Presumably, acid digestionunder these conditions hasthe ability to physically break thediscrete uniform spheres of silicapresent in the colloid to releasethe sodium present. Digestion ofaqueous samples (as received)was performed. The sampleswere also dried by oven heatingand were digested using the sameprocedure. Verification ofmethod reliability is accomplishedby the addition of sodiumspikes at varying concentrations.The precision of the resultsobtained from the modifiedprocedure is acceptable. However,the recovery of sodiumadded as a spike is consistentlydeficient. Before considering thisprocedure reliable, this anomalyshould be understood. Literatureresearch and additional testingare ongoing.Key accomplishments and milestones:• Literature research.• Collaborated with DuPont.• Continue testing the Ludoxusing different parameters forthe digestion procedure.Contact: W. Marshall (Wayne.Marshall-1@ksc.nasa.gov.), LO-G3-C,(407) 867-3910Participating Organizations: BoeingNorth American, Inc. (K. Marshall),DuPont (J. Ramsey), and LO-G3-C(D. Jackson and L. Wellington)58

Research and Technology 1998Inductively Coupled Argon Plasma Spectrometer[Thermo Jarrell Ash Corporation (TJA 61E)]59

Materials ScienceRadiant Heating FacilityIn order to perform testing onThermal Protection System(TPS) materials, a facility isrequired to simulate a variety ofsurface-heating conditions. In thecase of a vehicle reentering theEarth’s atmosphere, the heatingtakes place under low atmosphericdensity conditions.Within the Materials ScienceLaboratory, there was a need tobuild a small chamber that couldbe used to simulate reentryheating on various types of TPSmaterials. It was decided tofabricate a small 18- by 18- by 8-inch chamber that could beplaced inside an existing altitudechamber. With assistance frompersonnel at Langley ResearchCenter and Ames ResearchCenter, a small chamber wasdesigned and fabricated. Thechamber uses 24 infrared heatinglamps to provide high surfaceheating to reach temperatures ofover 2,200 degrees Fahrenheit.The chamber enclosure is fabricatedpartially from fused silicawith a density of 24-pound-percubic-footmaterial provided bythe Shuttle TPS facility. A powercontroller and separate temperaturecontroller allow the user toselect a ramp rate for the heating.Separate controls for the altitudechamber control the pressure inthe radiant chamber duringheating operations.Key accomplishments:• The chamber was fully activatedand tested to over 2,000degrees Fahrenheit.• Extensive waterproofingburnout support was providedto the Shuttle upgrade projectby looking at reducing the useof dimethylethoxysilane duringrewaterproofing in theOrbiter Processing Facility.Contacts: N.P. Salvail (Napoleon.Salvail-1@ksc.nasa.gov) and D.C. Lewis,LO-G3-T, (407) 867-1403Participating Organizations: UnitedSpace Alliance (M. Martin) and BoeingNorth American, Inc. (M. Gordon)60

Research and Technology 1998X-33 Rocket System Fuel TankElectrostatic CoatingThe X-33 rocket program willdemonstrate the key designand operational aspects of asingle-stage-to-orbit reusablelaunch vehicle. The fuel andoxidizer tanks are covered by theouter vehicle shell. This designallows a small air space betweenthese tanks and the outer shell,thus allowing a potential buildupof fuel and oxygen vapors in thespace. Just prior to constructionof the first vehicle, it was discoveredthat these tanks were coveredwith an insulating foam thathad dangerous electrostaticproperties. A search and testingsequence was then implemented.The final result was the selectionof a lightweight electrostaticcoating for all fuel and oxygentanks that would neutralize thecharge buildup in this confinedspace.The coating is in an inaccessiblelocation. The first coatingmaterial chosen was a clear,permanent, lightweight antistaticcoating. However, further investigationrevealed the coating hadto survive an elevated temperatureduring reentry and surviveas many as 25 launches withoutmaintenance. These additionalrestraints proved hard to satisfyand resulted in the testing ofmany coatings by the MaterialsScience Laboratory before asatisfactory coating was found.The final coating consisted ofsmall foam beads coated withsilver and applied with an epoxybase. The testing proved theantistatic properties under thehigh temperatures and the numberof cycles required.Contacts: R. Gompf (Raymond.Gompf-1@ksc.nasa.gov), A. Finchum,and N. Salvail; LO-G3-T; (407) 867-461961

Materials ScienceAnalysis of Chloropel by Direct Pyrolysis/FTIRInfrared spectroscopy is wellrecognized as a powerful tool inthe characterization of a widevariety of materials includingpolymers, biological substances,and semiconductors. Uniqueinfrared spectra act as a molecularfingerprint for materials.However, the information obtainedusing traditional FourierTransform Infrared (FTIR) analysismay be limited when analyzingopaque, nonvolatile, andcomplex polymeric samples. Forexample, signal masking andinterference may make it difficultto determine the composition ofindustrial polymer systemscontaining plasticizers, modifiers,and other additives.Thermogravimetric analysiswas used to design an appropriatetemperature profile. A heatingschedule of controlled rampingat 20 degrees Celsius perminute (°C/min) and isothermalholds at 290, 445, 700, and 900 °Cwas used to isolate characteristicpyrolysates.Infrared spectra obtainedfrom the neat material usinghigh-pressure anvil diamond celland attenuated total reflectanceyielded very similar spectra.Characteristics matching those ofa polyester plasticizer typicallyfound in polyvinyl chloride orchlorinated polymeric materialsdominate the spectra.These interferences may beovercome by combining infraredspectroscopy and pyrolysis, thethermal degradation of a materialin an inert atmosphere. As thesample is pyrolyzed, the additionof thermal energy causes moleculesto fragment according tothe relative strength of bonds. Apyroprobe inserted into the FTIRinterface places the quartz boatsample cell a few millimetersbelow the infrared beam. Materialsevolved upon heating asample pass through the infraredbeam path and are detected.The utility of direct pyrolysis/FTIR in elucidating the compositionof a complex polymericmaterial was demonstrated. Thedegradation of chloropel, a polymericfabric used in protectivesuits for hazardous operations,was investigated.Pyrolysis/FTIR providedadditional information thatfacilitated the identification ofother components in the chloropelmaterial. The spectra ofmaterials evolved at 250 °C (seethe figure) showed the loss ofhydrochloric acid (HCl) concurrentlywith the polyester plasticizer.This is evident in thedistinctive HCl pattern of sharppeaks overlapping the hydrocarbonstretching between 2,560 and3,060 wave numbers (cm -1 ).Spectra of another evolvedspecies contained characteristicsindicative of polyethylene. Residueremaining at temperaturesabove 1,000 °C indicates thepresence of an inorganic additive.In this study, components thatwere masked in traditionalinfrared analysis were identified62

Research and Technology 1998Polyester and HCl Pyrolysatesusing pyrolysis/FTIR. Chloropel was found to contain a chlorinated polyethlyene polymer,polyester plasticizer, and inorganic additive such as a coloring agent.Pyrolysis/FTIR was also used to study wire insulation that had significantly degradedand resulted in a failure. Pyrolysis/FTIR can provide valuable information intothe chemical composition and degradation process of polymeric and composite materials.Key accomplishments:• Developed method parameters for pyrolysis/FTIR using a pyroprobe.• Results indicate pyrolysis can be used to study the chemical composition and degradationprocess of polymeric materials.• This technique will be used in failure investigations and polymeric research.Contacts: M.K. Williams (Martha.Williams-1@ksc.nasa.gov) and J.J. Palou, LO-G3-C, (407) 867-3910Participating Organization: C.M. Bradford, NASA Scholar (Georgia Institute of Technology and SpelmanCollege)63

Materials ScienceHydrolytic Degradation of PolyimideWire InsulationPolyimide wire insulation haslong been the coating ofchoice because of its excellentelectrical, mechanical, and chemicalproperties. The most commonamong the wire insulations usedis the polyaromatic type that isroutinely synthesized by thereaction of pyromelliticdianhydride (PMDA) andoxydianiline (ODA). Investigationscarried out in the pastseveral years showed that thepolyimide class of wiring insulationswas the subject of muchdebate. Wiring problems wereencountered in the aircraft industrywhere it was found that theuse of alkaline cleaners in contactwith polyimide materials resultedin degradation of the coatings,thus resulting in fire hazards andelectrical shorts.Laboratory tests conducted atKSC revealed that polyimide wirecoatings show degradation whenexposed to hydrazine fuel. Hydrazineis used as a part of thepropulsion systems and auxiliarypower units (APU’s). The APU’sare used to power the hydraulicsystem of the Shuttle and otherspace vehicles. The hydrazinefuel has the property of acting asboth an oxidizing agent and areducing agent. It is also a weakbase.The laboratory tests conductedat KSC included reactionsof polyimide with dinitrogentetroxide, aqueous ammonia (30percent), anhydrous ammonia(100 percent), and hydrazine fuel(100 percent). Fourier TransformInfrared (FTIR) analyses wereperformed on the wire testsamples before and after exposureto the chemicals. Except forthe dinitrogen tetroxide, a reactionproduct was observed on allother test specimens. The reactionproduct consisted of a yellowpowder. Polyimides undergohydrolytic degradation whenComparison of Virgin and Exposed Polyimide (Ascending Order)64

Research and Technology 1998exposed to alkaline solutions, andthe yellow powder formed ischaracteristic of this reaction.The postreaction FTIR analysisof the test specimens indicatesthe presence of two spectralbands not observed in the virginpolyimide material (see thefigure). These bands occur atapproximately 1,650 and 1,550cm -1 . Literature references indicatethe degradation products forthis type of reaction are cyclichydrazides and amines. Thespectral bands observed thereforecorrespond to a carbonyl functionalgroup (1,650 cm -1 ) and theamine C-NH functionality (1,550cm -1 ).Each of the alkaline solventsexposed to the polyimide insulationsproduced the same reactionproduct; however, the hydrazinefuel reacted most vigorously. Thenext series of tests included onlythe hydrazine, but the test specimenswere exposed by direct- ordrip-type application, totalimmersion, and vapor exposure.Results showed all the polyimidecoatings reacted. After dissectingthe wire insulation, it was observedthat the hydrazine vaporseven penetrated the secondpolytetrafluoroethylene (PTFE)layer and also the subsequentpolyimide layers. The PTFE layerhad a thickness of 0.001 inch (anincreased thickness would serveas a better barrier).The aircraft industry is thoroughlyinvestigating this problemin light of recent accidents andbecause of the increased age ofmany of the aircraft still in service.As a result of degradationcaused by many alkaline cleanersused in the aircraft industry,several manufactures of polyimidematerials are now usingmore layers of PTFE and are alsosearching for new polymermaterials that can serve as chemicalbarriers (resistance to alkaline).Key accomplishments:• Data confirmed that exposureto hydrazine (and other alkalinechemicals) results in thedegradation of polyimideinsulation.• The volume of exposure andperformance of insulationshould be addressed wheninvestigating possible polyimideinsulation failures.Contacts: J.J. Palou (Jaime.Palou-1@ksc.nasa.gov) and M.K. Williams,LO-G3-C, (407) 867-3910Participating Organizations: WiltechCorporation and Langley ResearchCenter65

Materials ScienceEpoxy Bonding AgentsEpoxy resins are characteristicallystrong and resistant toheat, water, and organic solvents.It is for these reasons that epoxyresins are used in diverse applications,one of which is attachingstrain gages to stainless-steelbolts. Since epoxy resins arecapable of crosslinking withoutthe emission of volatile components,they are particularly suitedto application on imperviousmaterials such as stainless steel,aluminum, and glass, which canthen be bonded with little or nopressure.In an investigation involvinga strain gage attached to a stainless-steelbolt, erratic voltagereadings were observed. Visualinspection revealed the presenceof red liquid pockets in the epoxymaterial. The red liquid wasanalyzed by Fourier TransformInfrared (FTIR) spectroscopy formolecular composition and wasidentified as an uncured epoxymaterial. After removal of theepoxy from the top of the straingage, more uncured liquid wasfound next to the strain gagecircuit. Further analysis determinedthat the cure of the epoxymaterial was inhibited by moistureabsorption. Moisture increasesthe pH (more alkaline) ofthe epoxy’s curing agent. Thehigher pH can have corrosiveeffects on copper components,which along with electricalsupporting data suggested thefailure mode of the strain gage.Although there are severaltypes of epoxy bonding agentsavailable, this particular type is atwo-part system in which anamine is used to induce thecrosslinking/cure process.Amines are basic materials (pH isgreater than 7). The mixinginstructions for the epoxy statethat, after the amine curing agentis added, the epoxy should bemixed for 5 minutes and allowedan additional 5 minutes beforeapplying the epoxy. Simulationsof this application process in thelaboratory still indicated thepresence of uncured epoxy(confirmed by FTIR analysis).To evaluate the root cause ofthe curing problem and to identifyany interfering components,several tests were performed toassess the application process.Contamination from the flux(rosin) material used in solderingwas found to induce no adverseeffects (acidic pH was approximately6). However, as expected,when minute quantities of waterwere added, an inhibitory effecton the epoxy cure was observed.The application of the epoxyappeared to be most successful atroom temperature when theepoxy was mixed for 5 minutesand then applied after an additional10 to 15 minutes (may varywith the temperature and humidityof the room). The additionaltime allows for the crosslinkingprocess necessary to obtain a fullcure and decreases the interferenceof the moisture. The addi-66

Research and Technology 1998Note: A similar chemical pattern is exhibited in the fingerprint region of each infrared spectrum.Comparison of Liquid Amine Curing Agent and Reddish Liquid Contaminant (Descending Order)tional time will ensure a good cure and still be within the shelf life stipulated bythe manufacturer. Another recommendation for the application process is to usea nitrogen purge.Key accomplishments:• Results suggested a failure mode for the strain gage.• Recommendation for improvements in the application of epoxy used for straingages.Contacts: M.K. Williams (Martha.Williams-1@ksc.nasa.gov) and J.J. Palou, LO-G3-C,(407) 867-3910Participating Organization: LO-G4-E (J.A. Bayliss)67

Materials ScienceCryogenic Insulation Systems for Soft VacuumAcryogenic insulation systemfor an operation under a softvacuum was developed at theKSC Cryogenics Test Laboratoryin 1998. Conventional insulationmaterials for cryogenic applicationscan be divided into threelevels of thermal performance, interms of apparent thermal conductivity(k-value in mW/m-K).System k-values below 0.1 can beachieved for multilayer insulationoperating at a cold vacuumpressure (CVP) below 1x10 -4 torr.For fiberglass or powder operatingat a CVP below 1x10 -3 torr,k-values of about 2 are obtained.For foam and other materials atambient pressure, k-valuesaround 30 are typical. Newindustry and aerospace applicationsrequire a versatile, robust,low-cost thermal insulation withan overall performance in themoderate range. The target forthe new composite insulationsystem is a k-value below 3 mW/m-K at a soft vacuum level (from1 to 10 torr) and boundary temperaturesof approximately 77and 293 kelvin. Many combina-tions of radiation shields, spacers,and composite materials weretested from high vacuum toambient pressure using cryostatboiloff methods. System designconsiderations included installation,outgassing, evacuation,compression, and end effects. Asshown in the figure, significantimprovement over conventionalsystems in the soft vacuum rangewas demonstrated. The newlayered composite insulationsystem was also shown to providekey benefits for highvacuumapplications as well.Optimization of the insulationsystem for specific applications(such as liquid oxygen storage onMars, liquid nitrogen conduit forsuperconducting power lines,advanced launch vehicles, andShuttle upgrades) is planned for1999.Contact: J.E. Fesmire (James.Fesmire-1@ksc.nasa.gov), MM-J2, (407) 867-7969Participating Organization: DynacsEngineering Co., Inc. (S. Augustynowicz)68

Research and Technology 1998Thermal Conductivity as a Function of Cold Vacuum Pressure[Comparison of Layered Composite Insulation (LCI) and Multilayer Insulation (MLI)]69

Materials SciencePermanent Antistatic SCAPE Suit CoatingAresearch grant was given toBelland Corporation ofAndover, Maine, to develop aneasy-to-apply, permanent, clearantistatic coating. This coating isto be applied to the Self-ContainedAtmospheric Protective Ensemble(SCAPE) used during toxic fuelingoperations at KSC. The evaluationtesting is currently being done bythe electrostatics engineers of theMaterials Science Division (MSD).The SCAPE suits presentlyused for worker protection duringShuttle fueling operations areelectrostatically capable of generatingvoltages in excess of 20,000volts. This is a high voltage capableof producing catastrophicelectrostatic discharges. Thispotential was controlled in the pastwith an application of topicalantistatic spray. This solution hasseveral disadvantages. It is onlytemporary since the solution mustbe applied to the suit every hourduring work. There is an everpresentdanger if the antistaticmaterial is rubbed off during thework and there is some concernabout exposure to the spray duringapplication. If a worker becomesinjured, the ability of the rescueteam to remove the injuredworker is difficult due to the slicknature of the spray. The potentialhazard of not using this spraywas clearly demonstrated in aprevious incident where a smallfuel fire was ignited duringOrbiter Processing Facility operationsin the Orbital ManeuveringSubsystem pods. An electrostaticdischarge from the uncoated suitmaterial was the most probablecause of the fire.Test results of one promisingversion of the coating reduced themaximum suit voltage generationfrom above 20,000 volts to below1,000 volts. At this time, thetesting is concentrating on theadhesive properties and thechemical compatibility with avariety of fuels and chemicals.These test results are encouraging,and the coating seems toimprove the suit protection forcertain fuels.Contacts: R. Gompf (Raymond.Gompf-1@ksc.nasa.gov,) LO-G3-T, (407) 867-4619; M. Parenti, LO-G3-T, (407) 867-8433; and N. Salvail, LO-G3-T,(407) 867-140470

Research and Technology 1998NondestructiveEvaluationThe Nondestructive Evaluation (NDE)Technology program at the John F.Kennedy Space Center (KSC) includesthe development of inspection and verificationinstruments and techniques that canprovide information (external or internal) tohardware and component structures in anonintrusive manner. The technologyincludes, but is not limited to, laser, infrared,microwave, acoustic, structured light,other sensing techniques, and computer andsoftware systems needed to support theinspection tools and methods.The present effort in this discipline is beingdirected toward reducing Shuttle processingcosts using these technologies. The longtermeffort of the program is to developcost-effective NDE techniques for inspectingand verifying space vehicles and theircomponents during manufacture and tocontinue validating those items duringassembly/launch and on-orbit or duringspace flight.71

Nondestructive EvaluationCondition Monitoring and Fault Identificationin Rotating Machinery (CONFIRM)Loading of the Space Shuttleexternal tank with liquidoxygen is accomplished via apump/motor/bearing assemblylocated at the northwest corner ofLaunch Complex 39. Since theassemblage is vital to the successof any mission, it is continuouslymonitored to detect, identify, andassess its condition and takeappropriate actions to minimizethe impact on launch. Conditionor health monitoring technologiesthat are being considered for usefall into two major categories:Mechanical Vibration SignatureAnalysis (MVSA) and MotorCurrent Signature Analysis(MCSA). Also, the AcousticEmission (AE) technique and aLube-Oil Analysis (LOA) will beused as early warning tools forpredicting impending failures.Mechanical, electrical, and flowinducedproblems will be addressedin this multiyear researchprogram.The present effort is directedtoward the installation of apump/motor/bearing assemblageat the Launch EquipmentTest Facility (LETF) to simulateLaunch Complex 39. This setupwill provide a test bed for researchand development, testingof variable frequency drives, andhands-on training for launch padpersonnel. The assemblage willserve as a platform for the evaluationof newer online condition/health monitoring technologies.Such online machinery monitoringwill lead to improvements inoperational efficiency, eliminateshutdowns, reduce maintenancecosts, and prevent catastrophicfailures. Early detection andcorrection of impending failureswill significantly improve reliabilitywhile enhancing safety.Key accomplishments:• 1998: Implemented the liquidoxygen pump assemblage atthe LETF. Validated the use ofAE, MVSA, and MCSA techniquesin identifying rotatingmachinery defects.Key milestones:• 1999: Assess condition monitoringtechnologies and variablefrequency drives on the300-horsepower pump assemblage.Additionally, validatethe MCSA technique andcoordinate with MVSA methods.Contact: A.F. Rodriguez (Andres.Rodriguez-1@ksc.nasa.gov), MM-J2,(407) 867-7969Participating Organizations: DynacsEngineering Co., Inc. (R.N. Margasahayamand M.J. Ynclan) andInformation Dynamics, Inc. (L. Albrightand O. Varosi)72

Research and Technology 1998MotorPumpVibrationSensorAcousticEmissionSensorWater LoopSimulated LETF Water Pump Motor Facility73

Nondestructive EvaluationEvolved Expendable Launch Vehicle (EELV)Hydrogen TestingThis report describes the equipment, procedures, and qualificationtesting to be used to evaluatethe mixing of hydrogen andoxygen in the simulated plume ofthe EELV RS-68 engine. TheEELV engine is similar to theShuttle engine, which uses hydrogenas the fuel and oxygen as theoxidizer. These engines start theflow of hydrogen before oxygenis added during the launchsequence, and the oxygen flowstops before hydrogen upon shutdown. Both of these situationsleave hydrogen, which must beburned off before the area is safe.Therefore, this excess hydrogenmust be burned in a manner thatprecludes detonation. The procedureis to entrain oxygen from airin hydrogen to provide a combustiblemixture, then to ignite thismixture so a controlled burnoccurs.The primary objective of thistest program is to qualify acombustion ignition system thatwould burn hydrogen from anaborted launch. To simulate thefiring of the EELV engine, nitrogenwill be released into a 1/7-scale flame trench. These releaseswill last 0.7 second and willinclude hydrogen combustion aspart of the simulation. Thisproject has three phases: Phase 1requires analysis of ambientoxygen in nitrogen, Phase 2requires analysis of hydrogenadded to ambient oxygen innitrogen, and Phase 3 requiresanalysis of hydrogen burningwith ambient oxygen in nitrogen.To make these measurements,grab-samples of the atmospherewill be collected just beforerelease, during release, and justafter release. The sampler (seefigure 1) is constructed of sectionsof tubing linked between valvesso the flow rate of the samplematches the total tubing length.Therefore, each section representsa time history of the concentrationof the gases as they pass thesample inlet. The contents of thesample tubes will be analyzed bygas chromatography, a methodSample InSample OutSample TubesValvesPumpSample TubesSample FlowExhaust DuctFigure 1. Sampling Setup for One Point of Six Sample Points Across the Exhaust Duct74

Research and Technology 1998Figure 2. Sampling System With EELV Test Simulation Equipmentthat can measure the concentrationof each gas at 0.2percent.The sampling systemseen in figure 2 shows thesample lines, valves, andsequencer that times theopening and closing of thevalves which separate thesamples. The procedure tobe used will clamp thesample tubing on either sideof the valves to isolate thesample. This will allow a fastturnaround of the samplingsystem, since it will onlyrequire replacing the sampletubes with new precuttubing. The samples in thetubes can be analyzed by agas chromatograph independentlyof the EELV testing.Key accomplishments:• Developed a method to measurethe concentration profileas a function of time duringEELV testing.• Designed and produced sixunits to capture the testsamples.• Developed the sample introductionsystem for the gaschromatograph.• Demonstrated that the methodcould measure the concentrationof oxygen and hydrogen toless than 1 percent in nitrogen.Contacts: R.C. Young (Rebecca.Young-1@ksc.nasa.gov) and D.E. Lueck, MM-G2 (407) 867-4439Participating Organization: DynacsEngineering Co., Inc. (C.F. Parrish, C.J.Schwindt, T.R. Hodge, and P.H. Gamble)75

Nondestructive EvaluationThermography for Nondestructive Evaluationand Laser ShearographyNASA, United Space Alliance,Boeing North American, Inc.,and Dynacs Engineering Co., Inc.,engineers and scientists performedshearography and thermographyinspection of Atlantis(OV-104) payload bay doors atPalmdale, California. The payloadbay door structure is composedmostly of graphite-epoxyhoneycomb and laminate. Noexisting inspection can adequatelyinspect this compositestructure. Two new techniques,shearography and thermography,were used to inspect about 70percent of the structure shell in 7working days (one shift). Bothtechniques worked well regardingthe rate of inspection andsensitivity. Several defects weredetected, most resulting frommaintenance-induced damage.All suspect defects were corroboratedwith ultrasonic inspectionbefore defining any repair.These results are a continuingeffort at KSC to develop a reliableinspection method for composites.Two other vehicles, Discovery(OV-103) and Endeavour (OV-105), have had similar inspectionswith good results. Boeing haswritten specifications certifyingthese techniques for use on theShuttle.Future actions include developingthe sensitivity and accuracyof each technique in variousapplications, developing operatorprocedures and certification, andextending the applications toother areas including the externaltank and solid rocket boosterthermal protection system andleak visualization.Key accomplishments:• 1996: Discovery payload baydoor inspection.• 1997: Endeavour payload baydoor inspections and shearographyand thermographyspecifications published.• 1998: Revised shearographyand thermography specificationsto include a generalprocedure. Atlantis payloadbay door inspection.Key milestone:• 1999: Probability of detectioncurves for the most commoncomposites for the orbiter.Contact: C.K. Davis (Christopher.Davis-1@ksc.nasa.gov), PK-H, (407)861-3636Participating Organizations: UnitedSpace Alliance (K.R. Wagner), BoeingNorth American, Inc. (A.M. Koshti),and Dynacs Engineering Co., Inc.(J. Donahue)76

Research and Technology 1998Process/IndustrialEngineeringNASA’s Kennedy Space Center (KSC) is developingas a world-class spaceport technologycenter. Process/industrial engineering technologiesare integral spaceport technologies. From aprocess or industrial engineering (IE) perspective,the facilities used for flight hardware processing atKSC are NASA’s premier factories. The products ofthese factories are among the most spectacularproducts in the world – safe, successful Shuttle and expendable vehicle launches carrying tremendouspayloads. The factory is also the traditional domain of the discipline of IE. IE is different in manyways from other engineering disciplines because it is devoted to process design, management, andimprovement, rather than product design. IE also emphasizes the relationships of workers withsystems and processes. Spaceport processes have many unique aspects that require development ofinnovative IE technologies, such as complex and risky depot-level maintenance processes, highperformancesystem test and checkout procedures, and low-volume manufacturing processes.Process/industrial engineering technologies address the generic challenge of “doing more with less.”IE is typically used to optimize the operational phase of a program. IE technologies introduced earlyin the program life cycle (during concept, design, and development phases) generally deliver outstandingresults. The Space Shuttle is NASA’s first major program with a long-term operationalphase, and many current and potential future programs (i.e., the International Space Station, X-vehicles,and human space flight to Mars) also are projected to have lengthy operational phases. Therefore,the strategic importance of process/industrial engineering research and technology developmentto NASA is rapidly increasing.Technologies include methods, tools, techniques, and processes as well as hardware and software.Most IE technologies evolved from the need to improve shop floor productivity. IE technologies arenow successfully used to design and enhance every type of process in Government agencies, productionindustries, service industries, and academia. Therefore, spaceport process/industrial engineeringtechnologies can be effectively transferred to a variety of additional organizations.The growing need to do things better, faster, cheaper, and safer has improved the potential value ofprocess/industrial engineering technologies. The articles in this section are divided into five interrelatedareas of process/industrial engineering: Management Support Systems, Human Factors Engineering,Work Methods and Measurement, General IE, and Process Modeling and Analysis. Yourfeedback to the contacts listed in these articles is appreciated.77

Process/Industrial EngineeringManagement Support Systems:Goal Performance Evaluation SystemIn 1993, Congress passed theGovernment Performance andResults Act. A key requirement ofthis legislation is that all Federalagencies develop strategic plans.A 1997 Congressional reportgraded the strategic plans thatwere submitted. The reportnoted that agencies failed toexplain how their goals linked totheir day-to-day operations andto each individual employee’sperformance plans/appraisals.NASA’s Strategic Plan statesthat each NASA Center ImplementationPlan should be “…thecommunication tool used toenable the Center’s customers tosee that their requirements arebeing addressed and to ensurethat employees understand theircontribution to the highest levelstrategies and objectives ofNASA. The final linkage is madethrough each individual’s performanceplan appraisal” (fromNASA Strategic ManagementHandbook, October 1996). TheGoal Performance EvaluationSystem (GPES) was developed tomake this “final linkage” to bringthe NASA Center ImplementationPlan to the employee and toencourage strategic linking andimplementation at every level inthe organization.The potential for this researchwas to address the execution ofan agency’s strategic plan. Ultimately,the employees of anorganization are responsible forthe action planning, task execution,and accomplishments oftheir organization. However, fewtools exist that accommodatethese objectives or that focus onthe specific needs of a Federalagency. The GPES was developedto aid NASA in implementingthe Vision and StrategicObjectives outlined in the Agencyplan.The GPES was developed as aWeb-based strategic planning toolused for planning, managing, andevaluating employee contributionsto NASA Center and NASAwidestrategic objectives. Eachemployee performance plancontains objectives and strategiesderived from directorate-levelgoals and objectives. All directorateobjectives are electronicallyavailable in the GPES, includingthe links to higher level goals.The supervisor defines employeeperformance by selecting objectivesand strategies from a “dropdown” menu. Since the supervisorno longer has to write jobelements and performance requirementsfor every employee,the supervisor can focus onindividual goals. Employees canenter their achievements andtrack them throughout the year.Status reports are available at thedirectorate and Center levels.The GPES tracks the linksfrom directorate mission objectivesand mission strategies toAgency and Center strategies andlinks from individual performanceobjectives to directorateobjectives and strategies. Metricsare maintained for status ofperformance plans, links toobjectives and strategies, systemutilization, performance indicators,and the number of WorldWide Web accesses to relatedpromotional banners of interest toemployees.The GPES is fully operationalat KSC and is being used for the1998/99 employee appraisalperiod. The GPES was presentedand well received by all NASACenter Directors and the NASAAdministrator and is currentlybeing implemented at JohnsonSpace Center (JSC). The GPESsoftware continues to be enhancedwith additional features,such as:• Supervisor safety and healthmetrics (via an automatedpoint system)• Supervisor 360 assessmentfeature• Online performance award/evaluation• Online collection of communityoutreach activities for employeesKey accomplishments:• 1998: Successfully developedand implemented the WebbasedGPES for all Civil Servantsat KSC and implementedthe GPES for all Civil Servantsat JSC.Key milestone:• 1999: Continue deployment ofthe GPES to other MannedSpace Flight Centers.78

Research and Technology 1998COMMAND CENTERMANAGEMENTDefine Performance PlansConduct AppraisalPerformance AwardsOffice SummaryPerformance IndicatorsLeadership GuidePERFORMANCEInput Status & ActionsCenter Support LogEmployee ReportsManage StrategiesSYSTEMChange PasswordHELPLogoffGPES Command Center Menu:• Automates the employee performance appraisalprocess, from planning through appraisal.• Provides a direct link between overallorganization/directorate strategic plans andemployee performance.• Integrates business goals and objectives withdaily work processes.• Provides centralized data for summaryevaluation of organizational objectives.• Aligns resources toward successful achievementof overall goals/mission.• Affects behavior toward strategic thinking andimplementation.Beneficial software design attributes include:• Easy customization.• Intuitive graphical user interface.• Web-based or intranet application.• Integrated application using off-the-shelf tools.Contacts: C.J. Carlson (Christopher.Carlson-1@ksc.nasa.gov), ST-B, (407) 867-6450; J.C. Kunz,ST-B, (407) 867-6411; and L.B. Roe, ST-B, (407) 867-647279

Process/Industrial EngineeringManagement Support Systems: OrganizationalChange Models for Strategic ManagementStrategicPlanningGovernment organizations, asis the case with privateorganizations, are being requiredto change their present operationsto align with the ever-changingenvironment. Often this changeneed leads to a large-scale transformationincluding a change inmission or core business. Withthe change in mission, the organizationmust also change themanner in which it completes itscore business (i.e., the processes,tools, and people). One of thefirst steps in achieving successfulchange and transformation is tocreate a vision of the future.Strategic management has beenoffered as a method to driveorganizational change. Strategicmanagement is a continuousprocess aimed at aligning everydayactions with the long-termdirection of the organizationbased on the needs of the customer.An organization can usestrategic management to achievea set of strategic thinking outcomesand produce a set ofproducts to move the organizationforward. The objective ofthis research is to understand anddemonstrate the use of the strategicmanagement process to drivelarge-scale transformation.As shown in the figure, theprocess of strategic managementincludes the functions of strategicplanning, implementation planning,execution, and performanceevaluation. KSC used this processto develop a set of products:a strategic direction, projectplans, an initial set of performancemeasures, strategic results,and lessons learned.Strategic planning is a groupprocess by which the organizationdefines or refines theorganization’s mission (corebusiness statement), vision (idealfuture state), goals, and objectives.The process involvesunderstanding both the internaland external environments (e.g.,strengths, weaknesses, opportunities,threats, etc.). The output ofstrategic planning is an integratedset of goals, objectives, strategies,and projects to improve performance.PerformanceEvaluationCustomerSatisfactionExecutionStrategic Management ProcessImplementationPlanningFor KSC, the strategic planningprocess focused on defininga strategic direction with productsof a future state, core business,and strategic roadmap. TheCenter Director shared the messagevia a KSC-wide rolloutprocess he presented at an allhandsmeeting and then visitedwith each directorate at KSC. TheStrategic Plan became real80

Research and Technology 1998through the implementationplanning process.Implementation planning isthe process by which the organizationdevelops specific strategiesor actions to implement thestrategic direction and defines thespecific measures of performancethat will determine the progressof the planned actions. Implementationplanning provides thedetailed performance planningand proposed resource allocationto implement the Strategic Plan.An organization uses the implementationplan to guide day-todaybehavior or execution. Executionis the carrying out of theimplementation plan.Performance evaluation is theprocess by which the organizationunderstands the impacts ofthe projects on the goals andobjectives. The use of performancemeasurement and evaluationcreates tangible results thatcan be studied to produce lessonslearned and recommendations onhow to improve the organizationand adjust the Strategic Plan.The customer satisfactionprocess is the foundation for thestrategic management process byproviding information and knowledgeabout how KSC can meet andexceed customer needs.Key accomplishments:• 1997: Conducted an internal andexternal research study on thesuccess factors for strategicmanagement.• 1998: Conducted a cycle ofstrategic management with KSC.Key milestones:• 1999: Refinement of a set ofprocesses and integrated schedulefor strategic management.Development of a best-practicesmodel for deploying strategicmanagement.Contact: J.W. Lyons (Jennifer.Lyons-1@ksc.nasa.gov), AG, (407) 867-2512Participating Organization: University ofCentral Florida (T. Kotnour, Ph.D.)81

Process/Industrial EngineeringManagement Support Systems: MethodologyTo Harvest Intellectual Property at KSCInformation and data obtainedthrough problemsolving anddecisionmaking can be convertedinto intellectual capital. The needto acquire intellectual capitalcreated the knowledge managementmovement, which aims todevelop new practices and toolsto capture knowledge. Knowledgemanagement in general triesto organize and make availableimportant know-how, whereverand whenever it is needed. Thisincludes processes, procedures,patents, reference works, formulas,“best practices,” forecasts,and fixes. One kind of knowledgemanagement project attemptsto manage knowledgeassets from a financial perspective.KSC’s focus on this projectis on intellectual capital andharvesting little-used patents andintellectual assets. As the Centerresponsible for preparing andlaunching space missions, KSC isplacing increasing emphasis onits technology developmentprogram. KSC maintains avigorous applied research programin support of Shuttle launchactivities. Ground supportsystems, launch and processingfacilities, and environmentalprotection all require continuedattention for KSC to remain theNation’s premier state-of-the-artspaceport. Focusing predominantlyon applied researchprompted KSC to develop newtechnologies and expertise directlyapplicable to commercialproducts and manufacturingneeds.Technology commercializationis a primary goal of NASA’sTechnology Transfer Program.Patent and copyright licensingsare key mechanisms to accomplishthis goal. In order forNASA to continue to increase thenumber of successfully commercializedtechnologies, NASA mustidentify commercial applicationsfor its new technology and effectivelyseek out commercializationpartners.Key accomplishments:• 1997 and 1998: Alternativecommercial applications wereidentified for 11 KSC-developedtechnologies. Fourtechnologies were analyzed inthe last half of 1997 and sevenin the first three-quarters of1998. These advanced technologydevelopment projects havebeen proposed, are currentlyunder development at KSC,have been completely developed,or have already receivedintellectual property protection.Potential markets associatedwith the new applicationswere investigated, whichprovided profiles of key companiesthat may be interestedin partnering with NASA. Thecurrent state of similar or1201011101079710078Potential Markets80604015 1238225236200TDPCBPFMLAMSRMASSGLCSTAGMAPSECABLDPGPUFSHFDCUTechnologiesPotential Markets82

Research and Technology 1998applicable commercially available technology and potential fordual-use development with industry was investigated. Assistancein identifying and characterizing qualified leads associated withcommercializing NASA technologies was provided. Companieswere categorized primarily on the basis of capabilities, interests,and areas of expertise. A comprehensive report containing a synopsisof each advanced technology project as well as a review ofpossible partners and applicable commercially available technologieswas prepared. KSC was provided with 668 leads for potentialcommercialization partners and 110 new potential uses for thefollowing technologies (the figures show detailed information of thenew uses and potential commercialization partners):- Environmentally Controlled Abrasive Blastsuit (ECAB)- Hydrogen Fire Detector Calibration Unit (HFDCU)- Liquid Air Mixing System (LAMS)- Low Differential Pressure Generator (LDPG)- Mapping Analysis and Planning System (MAPS)- Particle Fallout Monitoring System (PFM)- Portable Ultraviolet Flame Simulator (PUFS)- Remote Monitoring and Alarm System (RMAS)- Supersonic Gas-Liquid Cleaning System (SGLCS)- Test Aerosol Generator (TAG)- Turbine-Driven Pipe-Cleaning Brush (TDPCB)Key milestone:• 1999: Ongoing identification ofalternative commercial applicationsfor additional NASAdevelopedtechnologies.Contact: G.A. Buckingham (Gregg.Buckingham-1@ksc.nasa.gov), HM-CIC,(407) 867-7952Participating Organizations: NASATechnology Programs and CommercializationOffice (K.W. Poimboeuf andD. Makufka) and Florida InternationalUniversity (I. Becerra-Fernandez)2522201515“New” Uses1510107106596550TDPCBPFMLAMSRMASSGLCSTAGMAPSECABLDPGPUFSHFDCUTechnologies“New” Technology Uses83

Process/Industrial EngineeringManagement Support Systems:KSC Customer Focus Process DevelopmentAs part of the KSC Strategic Roadmap, customer satisfactionhas been identified to be both an objective and a strategy.These customer satisfaction objectives and strategies will supportthe Center’s vision and will help in achieving KSC’s statedgoal as the worldwide launch site of choice. The objectives andstrategies will also drive improvements in KSC’s core capabilitiesby addressing the tools, expertise, facilities, and business processesthat support the customer. To address these customersatisfaction objectives and strategies, research was conducted incustomer satisfaction, which included customer elements fromthe Baldrige award criteria and President’s Quality Award.Based on the research, a customer focus model was developed(see the figure). The model delineates a six-element scopedefined as follows:1. Customer Knowledge: This element defines and segmentscurrent and potential strategic customers and identifies theirneeds, with additional information gathered regarding theirrequirements, expectations, and critical success factors.2. Customer Satisfaction Determination Tools and Methods:These processes include collecting feedback from multipletypes of methods over the duration of the customer experienceat KSC, feeding that information back to the appropriateorganizations, using the information to drive improvementprojects, and reporting the improvements back to the customer.3. Benchmark Best Practices: Benchmarking becomes an ongoingprocess of seeking out continual improvements in both thepractices and processes of improving customer satisfaction.4. Customer Satisfaction Leadership: This element uses theprevious element results to create a customerkeeping vision,to saturate KSC with the voice of the customer, and to developperformance expectations related to customer focus.5. Relationship Management: Relationship management usesprocesses for interfacing and supporting the customer tomaximize customer loyalty and retention and analyzes complaintsand lost customers.6. Customer Satisfaction Improvement and Results: This elementdevelops and tracks customer service standards basedon outcomes from the previous elements, including customersatisfaction metrics and customer business results for KSC.This model is being used as theblueprint to develop and implementprocesses and leadership fora customer-driven KSC. Onceimplemented, the results of theprocesses will be used as an integralcomponent of the Center’sstrategic planning efforts.Key accomplishments:• 1998: KSC customer baseidentified and segmented.Surveyed KSC management forperceived barriers and enablersof customer satisfaction. Completeda test case for the firstsegment for customer satisfactiondetermination. Reportedthe test case results to seniormanagement and to thosecustomers interviewed.Key milestones:• 1999: Determine customersatisfaction baseline for allsegments. Refine processes forall customer focus elements.Develop an Integrated ManagementSystem to assimilatecustomer data. Train KSCemployees for customer awarenessand understanding ofcustomer processes.• 2000: Implement the IntegratedManagement System. Establishand use processes for ongoingcustomer satisfaction measurement.Contact: L.K. Buckles (Linda.Buckles-1@ksc.nasa.gov), AG, (407) 867-2512Participating Organizations: Universityof Central Florida (J. Matkovich andT. Kotnour) and the KSC Customer FocusTeam (NASA, United Space Alliance, andBoeing)84

Research and Technology 1998CustomerFocus Model2.CustomerSatisfactionDeterminationTools and Methods4.CustomerSatisfactionLeadership1.CustomerKnowledge• Develop tools/surveys formeasuring customersatisfaction• Drive improvement• Report to customer• Create a customerkeepingvision• Saturate KSC with thevoice of the customer• Develop performanceexpectations• Customer satisfactionreviews6.CustomerSatisfactionImprovementand Results• Determine existing andfuture strategic customerbase• Determine critical successfactors in meetingcustomer expectations3.BenchmarkBest Practices• Determine benchmarkcriteria• Learn from bestpractices5.RelationshipManagement• Interface issues with thecustomer• Implement a complaintmanagement process• Develop customer loyaltyprocesses• Lost customer analysis• Customer satisfactionmeasurement• Implementation projects• Customer satisfactionprocess improvements• Customer satisfactionPresident's Quality Award• Expanding the customerbase85

Process/Industrial EngineeringManagement Support Systems:Balanced Scorecard MetricsDue to the requirements of theGovernment Performanceand Results Act of 1993, whichwas designed to improve theaccountability of Federal agencies,and to KSC’s commitment tomanage strategically, selectedindicators with performancetargets were needed to evaluatethe Center’s performance. TheKSC Strategic Roadmap had beendeveloped; however, to bring theroadmap to life, measures wereneeded to determine if thestrategy was being implementedand getting results. A lessonlearned from the National PerformanceReview study on metricssuggested that a specific frameworkshould be defined to developmeasures of organizationperformance.A team representing all areasof the Center was formed toanalyze the existing strategy andto understand the expectedoutcomes from implementingKSC’s strategy. A review of theliterature on organizationalmeasurement systems and inputfrom experts was balanced withKSC corporate knowledge ofcurrent operations. Small groupswere used to facilitate inspectionof the category functional areas.The Agency, enterprises, andCenter management were viewedas customers of the process.Seventeen high-level indicatorsthat were balanced between near-term and long-term outcomeswere selected. These metrics mapto Agency and Center goals andform the KSC balanced scorecard.As each high-level metric isdeveloped, it will be added to thechampion organization’s Web siteand linked to the KSC BusinessWorld Scorecard. The scorecardwill be reviewed each quarter atan executive management review.A “drill down” to lower levelmetrics that track to root cause/individual contributors will beadded. Each organization will betasked to define a “balancedscorecard” related to its productsand services.Key accomplishments:• November 1997: Senior managersreviewed each strategy inthe KSC Roadmap and attemptedto further define themwith metrics.• December 1997: 187 metricswere identified, at least one foreach strategy and objective ofthe KSC Roadmap.• January 1998: A team wasformed to refine the indicatorsfor consistency and linkage.• March 1998: The team beganto define a framework/approachfor KSC metrics.• April 1998: Roadmap indicatorswere grouped into eightcategories and evaluated tobalance across the Kaplan andNorton model.• May 1998: The Center Directorintroduced the KSC Scorecardat a Strategy Update Briefing toall employees.86

Research and Technology 1998Vision and Strategy Framework MetricsNot Met80706050403020Sample MetricMilestones Not MetGoalDefinitionMetric AreaLinkage toStrategic E100JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DECPlannedImprovementNot Met80706050403020Sample MetricMilestones Not MetGoalDefinitionMetric AreaLinkage toStrategic E100JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DECPlannedImprovementNot Met80706050403020Sample MetricMilestones Not MetGoalDefinitionMetric AreaLinkage toStrategic E100JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DECPlannedImprovementNot Met80706050403020Sample MetricMilestones Not MetGoalDefinitionMetric AreaLinkage toStrategic E• NASA Programs• Enterprises• Customer Agreements• Support Agreement100JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DECPlannedImprovementKSC Organizational Performance Measurement Structure• August 1998: Top-level indicators were selected for each scorecard category.• October 1998: Directorates were selected to champion each top-level metric.• November 1998: The KSC Scorecard was added to the Business World Web site with place holders foreach metric chart.Key milestone:• February 1999: A Center Performance Review was made using KSC Scorecard metrics.Contact: M.A. Bell (Michael.Bell-2@.ksc.nasa.gov), AG, (407) 867-2512Participating Organizations on the KSC Metrics Integrated Product Team: AF-A (G. Swanson), AB-G2 (D. Armstrong), AI(R. Sharum), BC (L. Buckles), EC-C (R. Tilley), EY-B-PA (B. Monson), FF-D1-A (R. Ponik), FF-I3-A (M. Steele), GG-C-B2(K. Buchner), HM-E (L. Boyd), JJ-5 (C. Quincy), LO (B. Franklin), LO (M. Stelzer), MM-H (A. Heard), OP-OSO(M. Krisberg), PH (S. Robling), PZ-A1 (T. Barth), and ST-B (J. Kunz)87

Process/Industrial EngineeringManagement Support Systems: Program Corporate Memory —a Knowledge Repository for KSCMany organizations depend ondecisionmakers to createmission-critical decisions that aregrounded on information fromvarious areas. The typicaldecisionmaker has a deep understandingof specific domains thataffect the decisionmaking processcombined with the experiencethat permits the individual toreact immediately and decisivelyon the knowledge. A prominentdecisionmaker has also gainedextensive experience and implicitknowledge from years of work insuch domains. An advancingtrend today is downsizing; manyorganizations make a consciousdecision to downsize in order tocut back spending and bettercompete in an increasinglyaggressive market. Among themany side effects of downsizingis the dissipation of the “knowledgeresources” of the organization;hence, organizations end updevitalized (e.g., decreasedmorale, commitment, quality,teamwork, productivity, andinnovation). To conserve theexisting knowledge, a practicalknowledge management (KM)system demands that it be obtained/produced,shared, regulated,and leveraged by a steadyconglomeration of individuals,processes, information technologyapplications, and organizationalculture. KSC is currentlyfacing a wave of employee turnoveras a result of Federal Governmentdownsizing, retirement,and work redefinition. In orderto prepare for these imminentorganization challenges, KSCcommissioned a KnowledgeManagement Assessment (KMA)study.In order to assess the areas ofintellectual capital for KSC, aKMA was designed and implemented.The purpose of theKMA was to (1) identify keycompetencies for KSC, (2) performa knowledge asset inventory,(3) perform a process evaluation,(4) analyze KM culturalreadiness, (5) perform a technologyevaluation, (6) develop a KMstrategy deployment roadmap,and (7) propose the necessarynext steps.For this purpose, a series ofKM assessment interviews weredesigned and implemented withthe cooperation of representativesfrom the majority of the functionalgroups at KSC. The goal ofthe KM interview was to assistKSC in identifying key competenciesand to analyze the currentknowledge architecture for theCenter. This step will ensure theappropriate methodology isrecommended at the end of thisphase. An important desired goalof this effort was to gather data toimplement a prototype that willaddress some of KSC’s KM needs.Anecdotal results of the KMAinterview for two functionaldirectorates at KSC are describedin detail in the project’s finalreport. The findings from theKMA included KM needs andpossible enhancements to theexisting KM environment. Thesefindings also comprise culturalneeds, which address the promotionof a knowledge-sharingculture versus a culture where“knowledge is power.”Key accomplishments and milestones:• A KMA study was designedand implemented betweenFebruary and April 1998. Inorder to accomplish the assessment,eight technical groupswere interviewed at KSC. TheKMA findings obtained fromthe groups interviewed revealedKSC’s KM needs andpossible enhancements to thecurrent KM environment.• Following the KMA interviews,two directorates were selectedby KSC executives for a 3-hourdetailed second-stage drilldowninterview. The twogroups chosen were the ShuttleProcessing and the PayloadProcessing Directorates. Thepurpose of the second-stagedrill-down interviews was toidentify a focus area to serve asa test bed for a KM application.Representatives from the twofunctional directorates wereinterviewed during the secondstageKMA.• Illustrative prototypes weregenerated for each of the fourrecommendations presented toKSC executives. The prototypeswere created using datafrom the groups at KSC. Findingswere presented to theexecutive team in July 1998.88

Research and Technology 1998• A written report was compiled and distributed to the executive team as well as to each of theparticipating directorates in July 1998. The written report also included a literary review onwhat organizations are currently doing in KM.• A number of presentations were made to some of the functional groups that participated inthis effort. Ongoing presentations are expected.• Proposals to address some of the required organizational KM systems were prepared andsubmitted.Contact: G.A. Buckingham (Gregg.Buckingham-1@ksc.nasa.gov), HM-CIC, (407) 867-7952Participating Organization: Florida International University (I. Becerra-Fernandez)KMA Summary of Findings: Knowledge Management Tools(Number of Functional Groups With Need for KM Tool/Total Functional Groups Interviewed)• Expert Knowledge Elicitation and Virtual Mentoring Tools: 6/8Elicit, capture, and transfer the knowledge of experts acquired through the years of experienceat NASA• Expert Seeker: 6/8Skills database with pointers to experts with a particular background• Collaborative Tools: 6/8Internet/intranet based tools that capture knowledge as teams create it• Decision Support and Expert Systems: 5/8Enhance decisionmaking and facilitate the decision process by incorporating knowledge factorsfrom past projects• Centerwide Lessons Learned Repository: 5/8Include a synopsis of why certain decisions were made, rather than simply which decisionswere made• Knowledge Management Procedures To Harvest Knowledge: 5/8Procedures to harvest organizational knowledge• Electronic Document Storage: 4/8Would allow departments and teams to share work files and relevant data• Centerwide Self-Assessment: 1/8Tool to identify what is organizationally known and what is unknown• Translation Software: 1/8For NASA documents and Web pages89

Process/Industrial EngineeringHuman Factors Engineering: Root-Cause Analysis SystemThe Root-Cause Analysis(RoCA) system helps engineersanalyze and track the rootcauses of process anomalies dueto human factors issues at theorganizational, team, and individuallevels. Such processanomalies include incidents thatcause personnel injuries, damagefacilities, incur additional costs,or delay processing. The systemis being implemented under aPhase II Small Business InnovationResearch (SBIR) contract.(RoCA is the new name of asystem originally called HF-TAS,for Human Factors Trending andAnalysis System.)The development of RoCA ismotivated by the weaknesses ofexisting root-cause analysistechniques. Although statisticalquality control methods (i.e.,methods for assessing whether aprocess is in control) are quantitativelyrobust, widely used, andsuccessful, only very simplequalitative methods (e.g.,fishbone diagrams) are availablefor root-cause analysis (understandingwhy a process is not incontrol). The result is that industriesfrequently spend millions ofdollars fixing the wrong processproblems. The other majormotivation for RoCA is the focuson the importance of humanfactors in industrial accidents.Research has shown that avoidablehuman errors are a significantsource of process anomaliesin many industrial processes (e.g.,aircraft manufacturing andmaintenance).RoCA has many possibleKSC, NASA, and commercialapplications. The first applicationof RoCA at KSC is assisting theHuman Factors Team in investigatingand analyzing the contributingcauses of Shuttle groundprocessing accidents. The majortechnical innovation of RoCA isthe anomaly process diagram(APD). The APD is a new, theoreticallywell-founded methodologyfor root-cause analysisfocused on the representation ofcausal, probabilistic relationsbetween process variables.RoCA is being developedthrough rapid prototyping withsignificant design inputs from theeventual user community (i.e., theHuman Factors team). Majorupgrades to the software weredelivered every few months in FY1998. The latest delivered versionincludes a new “qualitativeanalysis” module for graphicallyediting and relating the contributingfactors in an event investigationthrough an anomaly processdiagram. It also includes avariety of predefined, standardreports the user can produce withonly a few mouse clicks. Thesesoftware capabilities build uponpreviously delivered versions tohelp human factors analystsperform event analyses, communicatetheir analyses electronically,and understand the trendsin the mishap data using on-lineanalytical processing (i.e., pivottable) technology. Future versionsof the system will extendthe qualitative analysis capabilityto perform analyses quantitatively.Key accomplishments:• 1995: Phase I SBIR contractawarded.• 1996: Completion of the PhaseI feasibility study and demonstrationsoftware.• 1997: Award of the Phase IISBIR contract. Developed anddelivered the initial softwareprototypes to KSC.• 1998: Delivery of the firstRoCA system for operationaluse. Commercialization successof NASA-sponsoredtechnologies through smallbusiness acquisition. KSCdecision analysis workshop.Key milestones:• 1999: Refinement of operationalprototype at KSC. Additionalcommercialization ofRoCA and anomaly processdiagram technologies. Decisionanalysis workshop atJohnson Space Center supportingthe Exploration Office.Contacts: T.S. Barth (Timothy.Barth-1@ksc.nasa.gov), PZ-Q-A, (407) 861-6663; and J.R. Boogaerts, EI-HF, (407)867-7721Participating Organizations: Prevision,Inc., which is now part of Fair Isaac, Co.(R. Fung and B. Del Favero); UnitedSpace Alliance; NASA/Ames; andNASA/KSC (Shuttle Processing andHuman Factors Integration Office)90

Research and Technology 1998RoCA Analysis Entry Display91

Process/Industrial EngineeringHuman Factors Engineering: Applications inthe Checkout and Launch Control SystemKSC is recognized as NASA’sCenter of Excellence forlaunch and payload processingsystems. Due to the continuallyincreasing maintenance costs,technological obsolescenceproblems, limited system flexibility,and desire for improvedShuttle processing efficiencies, anew launch system is beingdeveloped. The Checkout andLaunch Control System (CLCS)will replace the current LaunchProcessing System (LPS). Byincreasing system reliability andreducing the hardware, softwarecode lines, and facility space, theteam projects a yearly operationalcost savings of 50 percent oncethe new system is fully deployed.Human factors is a specialtyconcerned with the well-being ofpeople in complex systems. Itfocuses on human beings andtheir interaction with products,equipment, facilities, procedures,and the environment. Threemajor human factors applicationson the CLCS project are:• Ergonomic assessment: Anergonomic assessment surveywas developed for the CLCSproject personnel. Overall, theavailability of basic ergonomicaids was determined to be low.Participants rated the intensityand frequency of pain ordiscomfort they feel in variousareas of their bodies. Thefigure summarizes the painintensity reported in the survey.Neck, shoulder, and lowerback were the areas cited withthe greatest frequency andintensity of pain among theCLCS personnel.• OMI conversion: Operationsand maintenance instructions(OMI’s) are the written work25Number of Responses201510NeckShoulderForearmWristFingersLower BackLegs501 2 3 4Intensity LevelsIntensity of Pain92

Research and Technology 1998instructions used to processShuttles and payloads. Theseprovide detailed step-by-stepinstructions for engineers,technicians, and inspectorsparticipating in the variousoperations and were writtenfor the existing LPS. As thenew CLCS software is implemented,the existing workinstructions will need to bemodified for the new system.A work measurement analysiswas performed to estimate thetime required to convert theseOMI’s. Approximately 950OMI’s from 24 Shuttle systemswere reviewed. Due to theuncertain nature of the conversionprocess, “best case,”“worst case,” and “most likely”scenarios were developed.• MMT console design: A significantportion of the CLCSproject is the replacement ofthe existing equipment in thefiring rooms. Several consoledesigns were considered forthe Mission Management Team(MMT) working in the firingrooms. Five ideas were developedfor the MMT consoledesigns. Console design andvendor selection is ongoing.Contact: L.K. Rupe (Linda.Rupe-1@ksc.nasa.gov), LM/CLCS, (407) 861-7323Participating Organizations: Universityof Missouri-Rolla (S. Murray) andLockheed Martin93

Process/Industrial EngineeringHuman Factors Engineering: Human Error Research in ShuttleProcessing and Aircraft Maintenance OperationsNumerous safety studies haveshown that the causes ofaviation accidents and incidentsare more likely to be related tohuman error than mechanicalfailure. However, human errormay occur both in flight and inthe ground operations thatsupport them. Several recentaviation accidents have determinedthe probable cause to bemaintenance related.Thus, there is a growingrecognition of the importance ofmaintenance human factors andthe need for operational research.Past accidents have dramaticallydemonstrated the potentialimpact of human error problemsin maintenance areas such astraining for maintenance andinspection, tracking of maintenanceresponsibility, proceduresand task documentation, workenvironment conditions, verbaland written communications, andleadership and teamwork.nance task aids that will ultimatelyreduce human error andenhance safety in maintenanceoperations.Striking similarities in humanfactors issues across Shuttle andaircraft maintenance have led totechnology transfer meetings ontopics of mutual interest. Figure1 shows the Shuttle in the OrbiterProcessing Facility, which has awork environment and workprocesses similar to those indepot-level aircraft maintenancecenters (see figure 2).This Ames Research Center(ARC) and KSC collaboration isintended to (1) promote humanfactors awareness, (2) exchangeresearch information and results,and (3) when feasible, conductjoint human factors researchusing KSC’s unique technologytest bed capabilities. These goalsare being accomplished in thefollowing ways:• Technology transfer workshops:The overall goal is toidentify issues, problems, and“lessons-learned” in commoninterest areas across spacecraftprocessing and aircraft maintenance.Topics such as humanerror and incident analysis, riskanalysis techniques, humanfactors training, and humanperformance measurement areincluded.Although the aviation industryhas been innovative in developingflight training technologies,human-centered automation,multimedia information, anddecision-aiding systems, theadaptation and transference ofhuman factors tools, techniques,and principles to ground operationshave been limited. The goalof this research is to better understandhuman error in maintenanceoperations in order toimprove procedures, traininginterventions, and other mainte-Figure 1. Space Shuttle Orbiter Entering Its Maintenance Facility94

Research and Technology 1998Figure 2. Aircraft Engine Maintenance• Human factors research: The goal is to combineresearch efforts that involve similar humanfactors goals and issues across multiple operationalsettings. KSC provides a test bed foroperations research in depot-level maintenance.These efforts demonstrate an area of synergybetween NASA’s Aeronautics enterprise and HumanExploration and Development of Space(HEDS) enterprise. In 1998, the NASA AviationSafety Program initiated an element focusing onhuman factors in aircraft maintenance operations.This program is closely coordinated with the FederalAviation Association and supports manyresearch efforts that can also apply to Shuttle operations.This opportunity has been used to increasethe collaboration between ARC and KSC and lookforward to valuable results supporting the goalsand objectives of both enterprises.Key accomplishments:• 1991 to 1993: Initial application of human factorstechnologies developed for flight crews to aircraftmaintenance crews. Team effectiveness researchon Shuttle maintenance crews. Memorandum ofunderstanding between ARC and KSC signed.• 1994 to 1995: Initial collaboration with the KSCShuttle Processing Human Factors Team in thearea of human error investigation and analysis.• 1996: Incident Investigation Workshop hosted byARC. This workshop focused on the humanfactors aspects of incidents, accidents, mishaps,and close calls in spacecraft and aircraft maintenance.• 1997: Human Factors Training Workshop hostedby KSC. This workshop focused on humanfactors training issues.• 1998: Written Procedures Workshop hosted byKSC. This workshop focused on work instructionsand task analysis (two task areas in theAviation Safety Program, Human Factors inMaintenance) and supported the Shuttle WorkInstruction Task Team and airline and militarymaintenance operations. Memorandum ofunderstanding between ARC and KSC updatedand signed by the Center Directors.Key milestones:• 1999: Continued collaboration in incident investigation,root-cause analysis, and task analysis.Possible workshop focusing on statistical processcontrol applications to system performance datacollected during maintenance operations. Formalizethe KSC process/industrial engineeringtest bed.Contacts: T.S. Barth (Timothy.Barth-1@ksc.nasa.gov), PZ-Q-A, (407) 861-6663; and B. Kanki, ARC, (650) 604-5785Participating Organizations: United Space Alliance,Transport Canada, National Transportation Safety Board,Aerospace Safety Advisory Panel, Northwest Airlines, UnitedAirlines, Continental Airlines, U.S. Airways, Idaho NationalEngineering and Environmental Laboratories, FederalAviation Administration, and U.S. Air Force95

Process/Industrial EngineeringWork Methods and Measurement:Expert System To Generate Job StandardsKSC industrial engineers areactively engaged in identifyingtechniques to improve theefficiency and effectiveness ofSpace Shuttle ground processing.One approach that has demonstrateda high potential forsuccess is the use of industrialengineering techniques to measurework. Although many workmeasurement techniques are bestsuited for short-duration, highrepetitionactivities, there are alsoapproaches to successfullymeasure the time associated withlong-duration, low-repetitiontasks like those inherent inShuttle ground processing.A challenge to work measurementpractitioners is that there isno guidance on which of severalavailable measurement techniquesto use. Practitioners mustrely on their own experience, onthe-jobtraining, previous approachesused by their predecessorsin the organization, and trialand error. These methods forchoosing a work measurementtechnique can lead to ineffectiveresults. The literature is of littlehelp and there are no referencesto guide the practitioner. KSCindustrial engineers have recognizedthis deficiency and havetaken steps to fill the void.In 1994, KSC industrialengineers and their supportcontractors began to develop anexpert system to (1) help the jobstandards developer select anappropriate measurement techniqueand (2) guide the jobstandards developer through thesteps required to develop a jobstandard when using a work timeestimation technique. The JobStandards Development System(JSDS) delivered to KSC in 1998asks questions relevant to techniqueselection and, on the basisof responses by the user, providesa list of techniques suitable forthe application. If desired by theuser, the JSDS will recommend aspecific technique determined tobe appropriate for the applicationdefined by the user.When estimation is the appropriatetechnique, the systemguides the user through dataacquisition from the domainexpert and computes the standardtime of the job. In additionto providing the standard time,the system provides an estimateof job duration and informationabout each resource required tocomplete the job.The JSDS has two primaryapplications. First, any organizationthat develops job standards(or less formal job time estimates)would benefit from the expertiseembedded in the work measurementtechnique selection moduleof the system. Second, the systemwill help organizations documentand quantify skill and work timerequirements for work composedof long-duration, low-repetitiontasks. This type of work is oftenassociated with equipment andfacility maintenance activities andfunctions. The JSDS extendssupply chain management downto the individual task level sincejob time estimates are an importantingredient to project scheduling.Candidates for commercial96

Research and Technology 1998application of the JSDS includeoperations of state and localgovernments, health care facilities,public utilities, and aircraft,rail, and ship maintenance andrepair facilities.Key accomplishments:• 1994: Successfully demonstratedthe prototype expertsystem to select an appropriatework measurement technique.• 1995: Identified the workmeasurement techniques toinclude in the expert system.• 1996: Conducted a small-scaletest of a work measurementtechnique in the KSC environment.• 1997: Conducted a comprehensivefield trial of the workmeasurement technique testedin 1996.• 1998: Completed the developmentof the JSDS. The JSDSincludes expert systems thatselect a work measurementtechnique, guide the measurementof work when work timeestimation is appropriate, andcompute the job standard.Key milestone:• 1999: Ongoing identification ofcommercial applications.Contact: M.M. Groh-Hammond(Marcia.Groh-Hammond-1@ksc.nasa.gov), PZ-Q-A, (407) 861-0572Participating Organizations:OMNI Engineering and Technology,Inc. (N. Schmeidler), Affinity LogicCorporation (G. Ribar), and UnitedSpace AllianceJob Standard Summary97

Process/Industrial EngineeringWork Methods and Measurement:Electronic Portable Information CollectionWork procedures for payloadprocessing and checkoutoperations at KSC are executedusing a paper system. With thissystem, a procedure is generatedusing a word processor. Theprocedure is then printed out,copied, and distributed to membersof the task team. When thework procedure is executed, asingle master copy is kept up todate by using a pen to record thetest data and notes and by usingquality and technician ink stampsto verify the work steps as theyare performed. Test team membersmaintain their own copies ofthe procedure. Deviations to thework instructions that occurduring the execution of theprocedure must be documentedon a paper form. These deviationsrequire approval signatures.Once approved, the deviation iscopied and distributed to the taskteam. The completed masterwork procedure, includingdeviations, is scanned into acomputer and stored electronically.The Electronic PortableInformation Collection (EPIC)system was developed to automatethis procedure. EPIC wasformerly known as the PortableData Collection (PDC) System.With the EPIC system, the procedureis converted from a wordprocessor document to a database.It is then executed usingportable computers. Data isentered electronically, either witha keyboard or a pen, using handwritingrecognition. The systemdistributes this data to all otherterminals. The ink stamp isreplaced with an electronic stampthat meets the form, fit, andfunction of the old ink stamp. Aprogrammable memory chipinside the electronic stamp storesa unique identifier. All teammembers have their own electronicstamp.This electronic stamp adds asecure mark to a step, identifyingwho performed that step and thedate and time the step was performed.The electronic stamp isread using a stamp reader connectedto the serial communicationport of the computer. Thesystem provides protectionmechanisms to ensure data andstamp integrity. Once the procedurehas been worked to completion,it is converted to a portabledocument format (PDF) andstored electronically in a documentationsystem.The main components of theEPIC system are the central dataserver (CDS) and the portabledata terminals (PDT’s). The CDSis the main computer that servesas the network host and databaseserver. PDT’s display proceduresteps and enable users to collecttest data and stamps. The PDT’sare standard personal computers(PC’s) running Windows 95 orWindows for Workgroups operatingsystems. Various PC’s areused as PDT’s, including desktops,laptops, wearable computers,and pen-based tablets. TheCDS is a high-end PC running theWindows NT operating system.The project was developedjointly by Sentel Corporation andKSC, the lead center for payloadprocessing. The prototype systemwas developed under a SmallBusiness Innovation Research(SBIR) contract that was awardedto Sentel Corporation to developthe capability to capture technicianand quality stamps and testdata electronically. The operationalversion was developedunder a Space Act Agreementbetween NASA and Sentel Corporation.The following benefitsare provided by the EPIC system:• All test team members seechanges to the documentinstantly, providing greaterassurance that all team membersare properly informed andthe data is accurate.• Accuracy of the procedure isimproved as deviations areincorporated directly into theappropriate sequence of theprocedure. The time to process,approve, and distribute adeviation is also reduced.• Information availability isimproved. Test data can besearched and retrieved througha standard database.• Queries can be made formanagement reporting orincident investigations.• The need to print and distributeprocedures prior to testingis eliminated.• The need to scan the procedurefor storage is eliminated.• Emergency procedures can beaccessed immediately.• Paper usage is reduced.98

Research and Technology 1998The system was modeled afterthe existing paper system usingthe existing business rules.Presently, the system is beingdeveloped to support SpaceStation processing. EPIC is beingmarketed to the airline industryfor use in airplane maintenanceand to the electrical power industryfor use in power substationmaintenance.Key accomplishments:• 1993: Completed the Phase Istudy for the SBIR contract.• 1996: Completed Phase II ofthe SBIR contract. Demonstratedthe proof of concept forthis system. Received theNASA SBIR Technology of theYear Award in the computer/software category. Completedpilot study 1. The first pilotstudy was conducted in theOperations and CheckoutBuilding using the EPIC electronicsystem in parallel withthe paper system.• 1998: Upgraded the systemfrom a prototype to an operationalsystem. In pilot study 2,tested the EPIC system in theKSC Space Shuttle Main EngineShop and Space StationProcessing Facility.Team Members Using EPICKey milestone:• 1999: Implement the EPICsystem to be used by NASA,Government contractors, andprivate industry.Electronic Stamp and Stamp ReaderContact: D.H. Miller (Darcy.Miller-1@ksc.nasa.gov),VC-B1, (407) 867-3523Participating Organizations: Sentel Corporation (K.L. Jackson and M.R. Kappel)and Mississippi State University (L.K. Moore)99

Process/Industrial EngineeringWork Methods and Measurement:Work Instruction Task TeamThe Shuttle Processing WorkInstruction Task Team (WITT)was chartered to develop andimplement a comprehensivevision for future work instructionsused in ground processingof the Space Shuttle fleet. Thegoals of the new work instructionsystem are to improve the efficiencyof the processes used togenerate and maintain the writtenprocedures, to improve theefficiency of shop floor taskexecution using the new procedures,and to improve workplacesafety by reducing the potentialfor human errors.The team analyzed the currentwork instruction generationprocesses and products (thewritten procedures). Severalopportunities for improvementwere identified to improve thecycle time and to reduce the laborhours associated with deliveringthe work instructions to the shopfloor to support a specific task.Existing work instructions arerule based, are highly detailed,and frequently contain informationnot needed for a specific task.Examples of nonvalue-addedinformation include drawings forother orbiter vehicles and worksteps for testing only performedat specified intervals. The writtenprocedures varied widely in“look and feel” for the users,which will become increasinglyimportant as workers are morefrequently assigned to differentorbiter and ground systems ordifferent facilities.The WITT collected data fromapproximately 20 different KSCteams working on various aspectsof improving work instructionprocesses. The team also gainedvaluable information and insightthrough participation in a WrittenProcedures Workshop co-sponsoredby Ames Research Centerand KSC. Finally, the teamcollected benchmark data duringsite visits to three different industryorganizations. The result ofthe team’s research was a visionfor the future of KSC work instructionsbased on the followingeight key actions:• Use a standardized format forthe work steps in all ShuttleProcessing procedures.• Increase shop involvement inthe authoring process.• Deliver “lean, clean workinstructions” with only theinformation needed for thecurrent task and a level ofdetail consistent with theresults of a task analysis con-StandardFormatTask AnalysisShopInvolvementMinimize Approvals,BuyoffsComputerizeWith COTSSkill-BasedWork ForceIncorporate WorkInstruction DeviationsMinimize Nontask-Related Data CollectionFigure 1. Key Elements of the Shuttle Processing Work Instruction Vision100

Research and Technology 1998sidering task frequency andcriticality/complexity.• Take advantage of KSC’s skillbasedwork force.• Minimize approval, buyoff,and closure requirements.• Incorporate all permanent,successfully executed workinstruction deviations prior torelease of the next revision.• Optimize the data collectionprocesses through innovativemethods to capture nontaskrelateddata and ensuring thatall data is analyzed and used.• Use the latest commercial offthe-shelftechnologies toenhance the new work instructionprocess.Key accomplishments:• 1998: Completed the work instruction vision and obtained approvalfrom KSC and Space Shuttle Program management to beginimplementation. Designed and implemented “test cases” to demonstratethe feasibility of the proposed new work instruction system.Supported a team to significantly reduce the number andcomplexity of the requirements for KSC work instructions. Developeda standardized format and writers guide (based on the Departmentof Energy’s guide) for implementation in all areas ofShuttle Processing. Developed an initial KSC task analysis procedurewith support from the University of Central Florida. Integratedefforts with several additional teams.Key milestone:• 1999: Charter implementation teams for all key vision elements.Contact: T.S. Barth (Timothy.Barth-1@ksc.nasa.gov), PZ-Q-A, (407) 861-6663Participating Organizations: NASA Shuttle Processing (R. Blackwelder,M. Wilhoit, and G. Glochick), United Space Operations (D. Blankmann-Alexander,D. Ciccateri, R. Corsillo, S. Defillips, J. Entinger, C. Hannas, K. Jones, B. Kidd,B. McKenzie, S. Morrison, V. Neal, J. Rooker, J. Swanson, and C. Jones), andUniversity of Central Florida (J. Pet-Edwards)The recommendations directlyaddress the root causes ofthe systemic problems associatedwith KSC’s written procedures.The relationship between theeight vision elements is shown infigure 1. The team also constructedseveral conceptualmodels showing the relationshipbetween task frequency/complexity/criticalityto the level ofdetail, skill-based training, andapproval/buyoff requirements.The level of detail model isillustrated in figure 2.High TaskFrequencyLow TaskFrequency• Minimum instruction detail• Maintenance manual for reference• Moderate instruction detail• Partial rule-based instructionsLow TaskCriticality/Complexity• Moderate instruction detail• Partial rule-based instructions• Maximum instruction detail• Rule-based instructionsHigh TaskCriticality/ComplexityFigure 2. Work Instruction Level of Detail Model101

Process/Industrial EngineeringWork Methods and Measurement:Industrial Engineering Decision Support ToolThe objective of this research was to develop a methodology for auser-friendly decision support software system for the applicationof innovative industrial engineering (IE) models and technologies forcomplex processes at KSC. To illustrate the feasibility of this approach,AET, Inc., developed a model for a KSC work process usinghistorical data collected over 10 Shuttle missions.The technical approach used for the modeling was the applicationof Multiple Regression Systems (MRS’s) for estimation of indirectwork content and performance. MRS applies the statistical techniqueof multiple regression to analyze the output of one or more operatorsengaged in a variety of tasks in order to estimate the time used toproduce a single unit of output for each of the tasks. This model isshown in the equation:Hours = 9.29 + 0.278 · Seq001 + 0.235 · Seq003 - 0.08 · Seq005 + 0.547 ·Seq006 + 0.318 · Seq008 + 0.017 · Seq009 + 0.062 · Seq024The coefficients in the model equation have special significance.They may be used to estimate the average time required to complete astep in each of the sequences analyzed. For example, 0.278 man-hourwould be the expected requirement for completing a step in sequence001. For illustration purposes as well as data limitations, the assumptionthat all steps in an individual sequence require equal amounts oftime was made. This equation may be used to predict the total manhoursrequired for any number of steps performed in any of thesequences.The application of this model in the area of decision support isextremely powerful. This model can be used to support changes insequence steps. By qualitatively predicting the number of work hoursrequired, a direct link to labor cost is established. Therefore, a decisionto change a process can be supported by objective data and notjust subjective estimates. The prototype software system is shown inthe figure.102

Research and Technology 1998Key accomplishments:• 1998: Phase 1 Small Business Innovation Research (SBIR)project. Performed statistical analysis on data collected from astructural bonding experiment. Identified, together with KSCground operations and IE personnel, appropriate work processesfor analysis and modeling. Developed an analyticalmodel of the process under study and gathered data for estimationof model parameters. Completed a final report specifyingthe technical results achieved in this project.Key milestone:• 1999: Potential continuation of research.Contact: T.S. Barth (Timothy.Barth-1@ksc.nasa.gov), PZ-Q-A, (407) 861-6663Participating Organizations: AET, Inc. (Dr. G.T. Hess) and Lehigh University(Dr. L. Martin-Vega)KSCIEProcessModelsSTADIUM TMUser-Friendly Simulation InterfaceSimulationControlDataControlDataAnalysisShuttleMaintenanceandProcessingDataStatisticalAnalysis,Risk Analysis,andDecisionModelingProposed Software-Based Decision Support System103

Process/Industrial EngineeringGeneral: Center for Applied Research inIndustrial and Systems EngineeringApartnership was developedbetween NASA and FloridaInternational University (FIU) toestablish the Applied Research inIndustrial and Systems Engineering(ARISE) Center. The partnershipseeks to establish a combinedresearch and educationalprogram to attract and retainwomen, Hispanics, AfricanAmericans, and other individualsfrom minority groups to engineering.Students participating inthe program:• Are exposed and trained inNASA’s mission.• Are given seminars on a varietyof issues, including therealities of the workplace,diversity, and gender issues.• Participate in applied researchprojects.• Are instructed on the benefitsof pursuing postgraduatestudies in the hopes of increasingtheir chances to succeed inthe workplace as well asincreasing their stature as rolemodels for future generations.• Have a 4-week on-site internshipso they become acquaintedwith the various KSCprocesses needed to completethe projects.• Receive a stipend during theacademic year and the summerterms.An important objective of thiseffort is to foster partnershipsbetween FIU and NASA andbetween FIU and local industry.The initial partners in this effortwere FIU in Miami, Florida, andKSC. FIU was the lead institution,whereas KSC providedsteering guidance and was asource to implement some aspectsof the program. The initialtimeframe of this effort was 2years. In this timeframe, it wasexpected that various aspects ofthe model should be tested,rethought, and retested as neededso the model could become anappropriate model for industryuniversitypartnerships. Specifically,a proposal was developedto begin selling the model to localindustry. The proposal highlightsthe benefits local industry mayderive from the ARISE Centerand the impact their sponsorshipwill have in shaping the lives offuture community leaders.Key accomplishments:• 1997:- Established an appliedresearch center where participatingstudents haveaccess to the necessary toolsto start and complete industrialand systems engineeringprojects related to NASAoperations and processes atKSC. Selected and set uphardware and software.Selected/purchased otherequipment needed for theARISE Center.- Recruited students, whichinvolved the development ofa brochure and the developmentof a Web site for adver-104

Research and Technology 1998tising the existence of this opportunity(arise.eng.fiu.edu/). Students from under-representedgroups who had a grade point averageof 3.0 were identified and a letter of invitationwas sent. Eight students were selected.- Developed activities for the ARISE Center thatwere attractive to students.• 1998:- Purchased computer equipment and software.The Center has one server, two networked laserprinters, and 15 PC’s. The Center has licensesfor a variety of software. The FIU industrialand systems engineering department providedlaboratory space and furniture to house theCenter.- Held six seminars, including an overview ofNASA, Space Shuttle history and assemblyprocess, and gender and racism in the workplace.- Visits to KSC for a special tour to see variousprocesses at KSC. Students participated in a 4-week internship during the summer. Thisinternship enabled them to work next to practicingengineers while developing theirprojects.- Students worked in teams of two on selectedprojects. Two projects were done for Logistics,two for Installation Operations, and one for theCheckout and Launch Control System (CLCS).- Curriculum Integration. Credit for projectswas given as part of a technical elective course.The projects were presented in the ProjectManagement course as well as in the 1998Annual Industry Projects Conference.- One-to-one conversations were used to let thestudents know what graduate school is allabout and how it can fit their career plans.- During the summer, a workshop was given onstatistical analysis to the Payloads office personnel.New avenues of collaboration wereinvestigated. New projects and liaisons wereidentified.- Fourteen students were recruited for the secondyear. New students will be selected inDecember 1998.- A proposal was prepared and is being discussedwith local industry. The Web site iscontinuously being updated.Key milestones:• 1998: Discussion of projects occurred in January,August, and December. Project developmentoccurred over the academic year. A ProjectsConference was held in April, which showcasedsome of the projects to industry. Continued theIndustrial Portfolio to recruit industrial partners.Seminars continued on a two-track level.• 1999: Projects Conference in April. A conferencepaper and journal paper will be published.Contact: M.M. Groh-Hammond (Marcia.Groh-Hammond-1@ksc.nasa.gov), PZ-Q-A, (407) 861- 5428Participating Organization: Florida International University(M. Centeno and M. Resnick)105

Process/Industrial EngineeringGeneral: Key Characteristics inManufacturing and MaintenanceKey characteristic (KC) methodologiesare used by a widevariety of companies to helpmanage variation risk in thedesign and manufacture ofcomplex products. Complexproducts can contain millions ofdimensions and characteristics(voltages, forces, etc.), each ofwhich impacts the performanceof the product. In addition, eachof these features as manufacturedwill deviate from its nominalvalue because of inherent variabilityin manufacturing, assembly,and environment. However,only a few of the millions offeatures, the KC’s of the product,will significantly affect the finalquality, performance, and cost ofthe product. The KC’s of aproduct link the product requirementsthat are variation sensitiveto the part and process characteristicsthat contribute to theirvariation.following: Allied-Signal discussedthe implications of KC’son suppliers; GE discussed thedesign for six sigma; Xerox,Kodak, and Boeing gave overviewsand examples of KC implementations;and IBM gave apresentation on the implication ofstatistical tolerancing.Four strategic research anddevelopment issues emergedfrom the 1998 symposium: howIdentify KC'sIdentify product-KC'sSet product-KC latitudesCreate KC flowdownto take a system view of variationrisk management, the meaning ofKC’s to suppliers, a potential U.S.standard for KC’s, and the costimplications and benefits of KCmethodologies. In addition,working groups were formed tocontinue discussions. Thesegroups are: Costs, Standards,Statistical Tolerancing, ProcessCapability Databases, Metrology,Supplier Relations, and Modelsand Tools. Information about theconferences, the working groups,and other KC resources can befound at the Web site: http://cardamom.mit.edu/KC/kc.html.KC methodologies includetools processes to identify theselect features, assess their impacton the quality of the product, andmitigate the effect of their variation.Variation mitigation techniquesinclude robust design,process control, variation reduction,and inspection. The figureshows a typical KC methodology.ProcessCapabilityDataDetermine which KC'sneed to be verifiedChart processDetermine which KC'sneed to have variation reducedReduce variationVariationModelThe first annual KC Symposiumin 1997 brought 40 peoplefrom 11 organizations together todiscuss general problems andissues surrounding KC implementation.The 1998 KC symposiumwas hosted by KSC. Thirteenpresentations included theDetermine which KC'sneed continual monitoringOngoing process controlTypical KC Methodology106

Research and Technology 1998Additional research and technology developmentwas proposed by developing KC spinoffcommon interest groups. KSC does not have highvolumemanufacturing operations like the organizationsrepresented by most existing KC symposiumparticipants, but the fundamental principles ofstatistical quality control (SQC) and key characteristicsapply to many other areas. KC methodologiesmay require customization in order to be useful inKSC operations. Potential spinoff common interestgroups could customize and apply basic KC andSQC methodologies to different domains. Twocandidate spinoff areas are:1. SQC applications to very low-volume or uniquespace hardware production: The potential existsto apply SQC techniques to the manufacture oflow-volume or unique hardware elements. Inthese cases, the data elements are usually operatingmeasurements of the machinery used toproduce hardware rather than the hardwareitself, since the extremely low-volume/uniqueproducts will not supply enough data for meaningfulstatistical analysis.2. SQC applications to aircraft/spacecraft maintenance(test and checkout) data: NASA andUnited Space Alliance system engineers arecurrently applying SQC analysis techniques toShuttle system performance data under theongoing surveillance effort. The analysis resultswill support certification of flight readiness(COFR) and identification of enhancement opportunities.The KSC COFR process now involvesverification of process stability and capability.Key characteristic methodologies can be appliedto select those system performance data sets mostimportant for determining flight readiness andopportunities for enhancements and upgrades.Based on preliminary research, it appears thatDepartment of Defense and industry aircraft maintenancecenters could also benefit from additionalapplications of SQC tools to system performancedata collected during maintenance operations.Key accomplishments:• 1997: First annual KC Symposium hosted by theMassachusetts Institute of Technology.• 1998: Second KC Symposium hosted by KSC.Strategic project approved to pursue funding fordevelopment of key characteristic methodologiessupporting KSC operations.Key milestone:• 1999: Third KC Symposium to be hosted byMotorola in Phoenix, Arizona.Contact: T.S. Barth (Timothy.Barth-1@ksc.nasa.gov),PZ-Q-A, (407) 861-6663Participating Organizations: Massachusetts Institute ofTechnology (A. Thornton), Allied-Signal, Alcoa, BritishAerospace, Chrysler Corporation, DARPA, Eastman Kodak,Ford, Embry-Riddle Aeronautical University, GE, GM,Honeywell, IBM, IDA, ITT, Lockheed Martin, NASA, NIST,Northrop Grumman, Pratt and Whitney, Quality Associates,Raytheon, Textron, Boeing, United Space Alliance, Universityof Florida, University of Maryland, and Xerox107

Process/Industrial EngineeringGeneral: Searchable Answer Generating Environment —a Knowledge Management System To Seek Expertsin the Florida State University SystemThe need to acquire intellectual capital has createdthe Knowledge Management (KM) movement,which aims to develop new practices and tools tocapture knowledge. An indepth examination ofcurrent KM projects revealed that a large percentattempt to create some kind of a knowledge repository.Current studies identify three types of knowledgerepositories. One of these types attempts tomanage organizational knowledge by storingpointers to those who have specific knowledgewithin the organization. In this light, this reportdiscusses the development of the Searchable AnswerGenerating Environment (SAGE) applicationprototype. The development of this applicationprototype was funded through the NASA/FloridaMinority Institution Entrepreneurial Partnership(FMIEP) grant.The purpose of this KM system is to create arepository of experts in the State of Florida StateUniversity System (SUS). Currently, each of thestate universities in Florida maintains a database offunded research, but these databases are disjointedand disparate. This application creates one singleWeb-enabled repository that can be searched in anumber of ways including research topic, investigatorname, funding agency, or university. The benefitsof SAGE are: (1) SAGE is a repository ofintellectual capital within the Florida SUS; (2) SAGEhelps locate Florida SUS researchers for collaborationwith industry and Federal agencies, thusincreasing the potential for research funding to theSUS; (3) SAGE enhances communication and grantsFlorida SUS experts more visibility, making universitiesmore marketable; and (4) SAGE combines andunifies existing data from multiple sources into oneuser Web-accessible interface.Ideally the aggregated data would be accessiblefrom one point of entry. For example, the databeing accessed may consist of multiple data typesthat have been converted to a standard file format.SAGE consists of the typical university-sponsoredresearch data incremented by object-oriented datasuch as research topic, investigator name, fundingagency, or university. One of SAGE’s advantagesis that there is only one point of entry or a Webenabledinterface, allowing multiple occurrences ofthe interface and giving the end user deploymentflexibility. The main interfaces on the query engine(in SAGE) use text fields to search the processeddata for key words, fields of expertise, names, orother applicable search fields. The applicationprocesses the end user’s query and returns thepertinent information. The information is collectedfrom a conglomeration of multimedia databases andthen presented as queried (see the figure).Key accomplishments (1998):• The development of the SAGE database involvedan initial design followed by the incrementalimplementation phases:- The initial design phase constituted a comprehensivesurvey of available tools and methodologies.An assessment was carried out toselect the most efficient approach to datastorage and data retrieval. A middlewaredevelopment environment was selectedbecause of its significant application strengthsand demonstrated database interaction capabilities.Additionally, it provided the abilityfor secure transactions.- The implementation phase of SAGE involvedthe design of the middleware modules, eachwith an assigned task. Querying moduleswere used to provide search capabilities. Eachquery interface involved several modules thatinteracted with the database.- A sample database was obtained from theFlorida International University (FIU) Division108

Research and Technology 1998UWF ExtractionAlgorithmUWFFAMUFSUUNFUFUCFUSFFAMU ExtractionAlgorithmUNF ExtractionAlgorithmFSU ExtractionAlgorithmUF ExtractionAlgorithmUCF ExtractionAlgorithmSAGEMiddlewareClientSAGEDatabaseSAGEWeb ServerFGCUFAUFIUUSF ExtractionAlgorithmFAU ExtractionAlgorithmFIU ExtractionAlgorithmState University SystemSponsored ResearchStandard Query Language (SQL)Compatible DatabasesFGCU ExtractionAlgorithmSAGE ArchitectureSAGE Interface (Web Browser)SAGE Applicationof Sponsored Research and Training (DSRT) toprovide a prototype data storage structure.After applying an extraction algorithm to thedata, the SAGE database was populated withFIU data.- The SAGE application was then Web-enabledon the primary server for its current wave ofbeta testing.- The SAGE prototype was then populated withthe University of Central Florida DSRT database.Some of the technical challenges facedduring the design and implementation of thisproject included the fact that databases fromFlorida SUS DSRT offices were dissimilar indesign and file format and in duplicate dataoccurrences, field names, and stored architecture.PERL scripts were used to solve thedatabase disparities, and a data dictionary wasimplemented to eliminate redundancies.Key milestones (1999):• Migration to a relational database structure iscurrently underway. This is a necessary stepbecause of its efficiency and scalability with data.The middleware source is currently beingrecoded to take advantage of the improved datastructures. This new relational architecture willalso alleviate the data inconsistency problemacross SUS platforms.• Population of the SAGE database with each of theremaining SUS DSRT databases.Contact: G.A. Buckingham (Gregg.Buckingham-1@ksc.nasa.gov), HM-CIC, (407) 867-7952Participating Organization: Florida International University(I. Becerra-Fernandez)109

Process/Industrial EngineeringProcess Analysis and Modeling: Statistical Process ControlTechniques for Variable Shuttle System Performance DataNASA Shuttle Processing has shifted to an insightfocus requiring the use of statistical techniquesfor analyzing system performance data to evaluateCertification of Flight Readiness (COFR), to determinerequirements for enhancement/upgrades, andto evaluate contractor performance. Several casestudies were developed to demonstrate the applicationof statistical techniques to assist in the insightrole. Case studies completed during this projectanalyzed Space Shuttle system performance dataengineers identified as critical variables indicatingthe health of the associated system (see the table).The analyses provided information that could beused to determine if there is evidence to support theneed for a system enhancement/modification.One of the studies supporting an enhancementwas the potable water case study. Water is a keyingredient to a successful Shuttle mission. Waterstorage space aboard the orbiter is limited to fourpotable water tanks with a usable capacity of 165pounds. Astronauts also use water generated as abyproduct of the electrical generation system whenhydrogen and oxygen are combined in the orbiter’sfuel cells. The water produced by the fuel cells isstored in the potable water tanks for use duringflight. It is important to ensure the quality of thewater is satisfactory for human consumption. Tomonitor the quality of the water, the nickel concentrationis measured. Analysis of the nickel concentrationrequires monitoring the stability of the nickelconcentration for each vehicle. To monitor thestability of the nickel concentration, Individual Xand Moving Range charts were constructed for eachvehicle at 15 (L-15) and 3 (L-3) days prior to launch.In the case of Atlantis (OV-104), the Moving Rangechart indicated a stable process, while the IndividualX chart demonstrated a statistically significantpattern indicating that the nickel concentrationshave increased significantly beginning withSTS-66. Research shows this coincided with anextended maintenance period at Palmdale, California.Prior to using the statistical analysis tools,system engineers plotted the nickel level versus themission. The resultant charts made it appear theremay have been a worsening nickel level. This casestudy, however, showed the process to be stableafter the initial step function increase was noticed.If statistical quality control techniques had beenused, systems engineers would have reconsideredthe conclusion to remove and replace the existingchilled heat exchanger because of the “apparent”continuing increase in the nickel level.Key accomplishments:• 1994: Completion of variable-form data collectionand analysis on two Thermal ProtectionSystem processes.• 1995: Collaboration with USBI for analysis andimprovement of solid rocket booster processes.An orbiter structural bonding process improvementeffort was initiated.• 1996: Phase II of the structured experimentationsupporting the orbiter structural bonding processimprovement was completed.• 1997: Held a series of three workshops for NASAand contractor engineers to develop skills incollecting, analyzing, and interpreting resultsfrom variable-form data.• 1998: Case studies depicting the application ofstatistical techniques to evaluate COFR anddetermine requirements for enhancements/upgrades were developed.Key milestones:• 1999: Implementation of statistical techniquessupporting process analysis throughout ShuttleProcessing. Implementation of process improvementsrecommended through the case studiesand measurement of the effectiveness of processchanges. Investigate potential technology transfer/synergyto the Orbiter Reliability-CenteredMaintenance effort, Checkout, Launch and110

Research and Technology 1998Control System project, and Integrated Vehicle Health Monitoring. Investigation of key characteristicmethodologies for selecting system performance parameters on which to apply statistical process controltechniques.Contacts: T.L. O’Brien (Timothy.OBrien-2@ksc.nasa.gov), PZ-Q-A, (407) 861-3968; and T.S. Barth , PZ-Q-A, (407) 861-6663Participating Organizations: Embry-Riddle Aeronautical University (D. Osborne), NASA/KSC Shuttle Processing (S. Minute,V. Elentri, T. Draus, H. Johnson, S. Greenwell, C. Estrada, C. Mariano, and F. Jones), Boeing (T. Damoff), United SpaceAlliance, and University of Central Florida (Y. Hosni and R. Safford)Case Studies Demonstrating the Application of Statistical TechniquesOrbiter SystemThermal Protection SystemData and Subsystem StudiedNose landing gear door corner laser step and gap measurementsOrbiter processing facility dewpoint temperature measurementOrbiter StructuresGuidance, Navigation, andControl SystemMain Propulsion SystemOrbiter Maneuvering System/Reaction Control SystemEnvironmental Control andLife Support SystemOrbiter MechanismsBond pull testsADTA/AADT test set transducer data from air data systemLH 2 , LO 2 , GH 2 , GO 2 , and helium subsystem dataOMS/RCS helium isolation valve data from the helium pressurization subsystemPrimary RCS regulator data from the helium pressurization subsystemNickel concentration data from the supply and waste water management systemExtension times from the landing gear subsystemOrbiter/ET umbilical bolt ultrasonic measurement data from the orbiter/externaltank separation system111

Process/Industrial EngineeringProcess Analysis and Modeling: IntelligentAssistant for Optimization ModelingOver the last 40 years, theversatility of optimizationmodeling has established it as apopular decisionmaking aid.Optimization encompasses a suiteof powerful decision supportparadigms that enable the modelingof any decisionmaking environmentin terms of objectives,decisions influencing the objectives,and constraints binding thedecisions. However, the potentialof these powerful techniques hasremained largely unharnesseddue to the following inherentdifficulties in constructing optimizationmodels:1. Optimization models typicallyaddress aspects of the domainthat are often hidden or invisibleto casual observers.2. Highly specialized skills arerequired to design and generateexecutable models.3. Optimization-based decisionsupport systems typicallydepend on building customsolutions for different domainsituations.4. There are few available toolsable to leverage the expertise ofdomain experts.Preliminary research toalleviate these difficulties wasconducted under a Phase I SmallBusiness Innovation Research(SBIR) contract. The centralproduct of this effort was aprototype implementation of theOptimization Modeling Assistant(OMA). Several key Phase Iobjectives were realized duringthis initial effort. The researchteam developed a structuredmethod of optimization modeldevelopment and created astructured, ontology-basedmethod for knowledge acquisitionand analysis. Another keyobjective was to develop a knowledgebase of heuristics, principles,and rules that assist inoptimization model development.Templates were created thatencapsulated the knowledge ofoptimization modeling paradigmsfor both applicationspecificand generic modeling.The Phase II technologyhardening efforts identifiedanother important factor thatlimits widespread application ofoptimization techniques topractical problems: the unavailabilityof much of the informationneeded for developing optimizationmodels. While optimizationtechniques provide analyticallysound solutions, their successhinges on the availability ofaccurate input data. Often, theinput data required to developvalid optimization models doesnot exist or is unaccessible inmost domains. Recognizing this,Knowledge Based Systems, Inc.,expanded the architecture of thePhase II OMA to include simulation-basedoptimization. Simulationwill be used to generate thenecessary input data, which isthen used by OMA for optimization.Using the two powerfuldecision support techniquestogether, OMA will delivercomprehensive decision supportanalysis capabilities to managersand decisionmakers. The enhancedOMA software implementationwas completed in 1998 (seethe figure).Phase III activities planned in1999 include (1) exercising theOMA software with KSC domaindata, (2) refining the OMA forcommercial applications, and (3)demonstrating the OMA onsustainment and remanufacturingapplications at Tinker Air ForceBase, Oklahoma City, Oklahoma,as part of another Phase II SBIRinitiative.Key accomplishments:• 1996: Completion of the PhaseI SBIR contract. Developmentof a prototype OMA. Selectionfor Phase II follow-on research.• 1997: Defined the OMA prototypeand templates. DesignedOMA extensions for simulation-basedoptimization. DevelopedKSC process modelsfor the OMA application.• 1998: Prototyped simulationbasedoptimization. CompletedOMA implementation.Acquired KSC domain data forthe OMA application.Key milestones:• 1999: Complete the OMAapplication at KSC. Demonstratethe OMA at Tinker AirForce Base. Commercialize theOMA.Contacts: T.L. O’Brien (Timothy.OBrien-2@ksc.nasa.gov) and D. Correa,PZ-Q-A, (407) 861-5428Participating Organization: KnowledgeBased Systems, Inc. (Dr. P.C. Benjamin)112

Research and Technology 1998Knowledge AcquisitionInterrogatorProcess andOntology CaptureExperimentCaptureTopology andTemplate MatcherTemplates andMapping RulesOptimizationDesignerDomainModelsSimulationDesignerExperimentSpecificationsOMA Conceptual ArchitectureOptimization ModelingOptimizationModelsOptimizationEnginesSimulationEnginesSimulationModelsSimulationOptimizationManager113

Process/Industrial EngineeringProcess Analysis and Modeling:Vision Spaceport Model DevelopmentKnowledge Base • Affordability DriversConceptOperationsFactorsDemand DrivenEconomics(lb/year)Concept DesignQuestionsThere is a need for a betterunderstanding of the interactionsthat occur between flightsystems and their requiredlaunch infrastructure (the spaceport).Visibility and understandingof these interactions areneeded to dramatically improvethe design of future launchsystems with a focus on reducingthe cost of access to space. Areduction in the cost can only beachieved with designs thatimprove life-cycle cost factors,one of the main objectives of theVision Spaceport project. TheVision Spaceport project has agoal to develop models that allowvehicle designers to understandthe effect of vehicle design parameterson spaceport operations.Payload/Cargo Processing FacilitiesTraffic/Flight Control FacilitiesLaunch FacilitiesLanding/Recovery FacilitiesVehicle Turnaround FacilitiesVehicle Assembly/Integration FacilitiesVehicle Depot Maintenance FacilitiesSpaceport Support Infrastructure FacilitiesConcept-Unique Logistics FacilitiesTrans. Sys. Ops Plan. & Management Fac.Expendable Element FacilitiesCommunity Infrastructure12Spaceport OperationsModules/FacilityFunctionsNonrecurring Factors(Vehicle Development Cost,Purchase Costs, etc.)Module Assessment IndexDatabaseSINGLE VehicleProductivityMeasures ($, Times,Each Facility)FLEET/SPACEPORTProductivity Measures($, Times, # of Facilities,# of Vehicles)Life Cycle Measuresand $/lb vs. Flight RateFigure 1. Spaceport Model Definition and AATe Basic StructureThe required models will providevehicle designers with criticalmeasures of performance thatdefine system costs (for example,single vehicle flight rate, the typeand number of facilities required,and the cost of operations perflight).During the summer of 1998, aVision Spaceport project taskdeveloped a prototype model thatcombined a knowledge-basedapproach with existing data. Themodel, called the ArchitecturalAssessment Tool - enhanced(AATe), is traceable to the nationalteam called the SpacePropulsion Synergy Team andsupports NASA’s Highly ReusableSpace Transportation study.The tool uses a series of multiattributeutility functions tocorrelate concept design parametersto spaceport facility requirements.These functions capturenot only the relation of a particularchoice to the outputs but alsothe strength or importance of thebroader context being addressed.In this way, the model behaveswith some similarity to “realworld” interactions and thusreflects cost and performancecause and effect.The cost assessment for avehicle concept is based on how itinteracts with 12 generic spaceportoperational modules (figure1) that represent functional costcenters. Each module has aknowledge-based utility functionthat is calculated as the userinputs the concept vehicle (figure2). Inputs consist of a set of114

Research and Technology 1998Figure 2. User Interfacequestions for the concept beingassessed, and these questions arebased on the knowledge captureof spaceport cost drivers. Thedata set used to calculate themeasures of performance includesa baseline (the Shuttle inthis case) as well as a series ofextrapolations, which are higheror lower costs and cycle times.Key accomplishments (1998):• Model methodologies thatintegrate flight architectureswith the ground infrastructure(spaceport); that correlatespaceport modules to anintegrated single vehicleperformance (flight rate,operational cost, and investmentcost); and that assess lifecyclecosts for various demandscenarios.• Software that tested all thepreviously mentioned methodologies.Key milestones (1999 and 2000):• Working product for top-levelvehicle system architectures.• Use of the tool in space launchassessments.Contacts: C.M. McCleskey (Carey.McCleskey-1@ksc.nasa.gov), PK-K,(407) 861-3775; E. Zapata, PK-G, (407)861-3955; and R.E. Rhodes, PK-G, (407)861-3874Participating Organizations: AmesResearch Center, Command and ControlTechnologies, Boeing, Lockheed Martin,United Space Alliance, University ofCentral Florida Center for Simulationand Training, and Florida Gulf CoastUniversity (A.J. Ruiz-Torres)115

Process/Industrial EngineeringProcess Analysis and Modeling: Intelligent Synthesis EnvironmentIn recent years, NASA has beenchallenged to perform missionsunder reduced budgets anddecreased timelines. NASA hasalso recently implementedchanges in structure that reduceduplication of engineering resourcesthroughout the Agency.Centers of Excellence have beenestablished to focus technicalexpertise in response to a shrinkingwork force. Therefore, manyengineering tasks that once couldbe accomplished completelywithin one NASA center nowmust be distributed among thecenters to capture the necessarylevel of technical expertise. Thedistributed nature of NASA’stechnical expertise and the needto perform in a “faster, better,cheaper” environment havedriven the Agency to developnew capabilities. At the sametime, NASA has been asked tohelp lead U.S. companies into the21 st century through a deploymentof cutting-edge systems at alevel of affordability that has notbeen seen to this date.The Intelligent SynthesisEnvironment (ISE) program seeksto address the geographicalchallenges as well as help improvethe engineering tools,technologies, and methodologiesfor NASA and U.S. industry. Ingeneral, these have not advancedsignificantly over the past severalyears. A plan is being madewhereby technologies developedin the NASA research centers ortheir partners are deployed asprototypes across the Agency. Asthese become mature, contractorschosen to maintain the prototypeswill be able to market them toU.S. industry. With the commercializationand subsequent reductionof the cost of these systems, itis hoped the private sector will beable to benefit from the systemsengineering efforts funded byNASA.The Agency started theprocess this year by deploying aCollaborative Engineering Environment(CEE) infrastructureacross the Agency. Each centerreceived one of the Core CapabilityRooms with the option to buymore out of their own budgets.The Core Capability Roomscontain audio and videoconferencing as well as a dataconferencing capability throughnetmeeting. These rooms aremaintained through a contractorset up to handle the Agency’sneeds.Reentry Thermal Analysis (From Langly Research Center)In the next year, the plan is todeploy the Immersive Environment(IE) or 3-D data visualizationtools as well as a data storageinfrastructure to support Agencywidereality conferencing. Withthese tools in place, the Agencywill have the capability to developand run systems through acomplete life cycle in a syntheticenvironment. This will aid in theunderstanding of the complexissues involved in the developmentand deployment of spacetechnologies without reliance onexpensive physical modeling orpaper analysis.116

Research and Technology 1998International Space Station Simulation (From Langly Research Center)In the future, NASA as well as industry and academia partnerswill develop new tools and methodologies that address the flow ofinformation from initial concept through manufacturing.Key accomplishments:• 1998: The NASA ISE Team was formed; the initial kickoff meetingwas held; and the initial collaborative infrastructure was deployed.Key milestone:• 1999: Install IE’s at all centers and a data storage infrastructureacross the Agency.Contacts: M.P. Conroy (Michael.Conroy-1@ksc.nasa.gov), VC-B1, (407) 867-4240;and T.E. Fredrickson, MM-G1-B, (407) 867-2970117

Process/Industrial EngineeringProcess Analysis and Modeling:Virtual Shuttle Processing ModelThe Virtual Shuttle Processing(VSP) Collaborative EngineeringEnvironment (CEE) project isdeveloping new engineering toolsand capabilities at KSC. The newtechnologies allow engineers tobring their efforts to the next levelof excellence and standardizetheir use across all NASA centers.Level 1 consists of basic dataconferencing and is being providedthrough ODIN for KSCdesktops and some conferencerooms. Level 2 consists of audio,video, and data conferencing.Level 3 adds the immersiveenvironment and reality conferencingcapability to the audio,video, and data conferencing.The VSP model is beingdeveloped to enhance engineeringdesign, improve processing,and enhance technical training.Maintenance of the Shuttleorbiter in its processing facility isbeing modeled.Key accomplishments:• 1998: Project initiation. Deliveryof Level 1 and Level 2 CEEcapabilities.Key milestone:• 1999 and beyond: Delivery ofLevel 3 CEE capabilities andmultiple applications.Contacts: M.M. Groh-Hammond(Marcia.Groh-Hammond-1@ksc.nasa.gov), PZ-Q-A, (407) 861-0572; andK. Iftikhar, PZ-Q-A, (407) 861-6671Participating Organizations: UnitedSpace Alliance, Boeing Aerospace, andNASA/Ames118

Research and Technology 1998Automationand RoboticsThe Automation and Robotics program at the JohnF. Kennedy Space Center (KSC) is focused on advanceddevelopment cutting-edge technologies toenhance KSC’s core mission of launch and landingground operations. The program also provides apartnering with other NASA research centers to demonstrateadvanced mobile base ground processing technologiesfor problems that must be addressed and solved forfuture space missions, such as remote autonomous Marsoperations. In this role, KSC is developing state-of-the-arttechnologies in sensors, mechanisms, manipulators, and mobile bases for ground operations thatcan be applied to future NASA mission scenarios. This field testing has selected space missiontechnologies that are also applicable to ground processing applications and problem areas. KSCprovides the opportunity to take these technologies out of the laboratory and apply them toactual ground operations at KSC. Technologies addressed in this section include advanced cableinspection capabilities, improved data collection and intuitive graphical user interfaces, andautomation of large mechanical load-carrying devices.Technology areas that KSC is working to develop and apply include: integration of real-timecontrols with advanced information systems, obstacle-avoidance sensors and systems,multidegree-of-freedom robotic devices and systems, intelligent control systems, imbedded anddistributed controls, inspection sensors and systems, integration of advanced software technologiesin control and sensor interpretation, and model- and rule-based systems for health monitoringand diagnosis. All these technologies can be applied to automating ground processing tasks.Application areas that are currently being addressed in this year’s report include the SolidRocket Motor Stacking Enhancement Tool, Automated Ground Umbilicals, and the Cable LineInspection Mechanism.119

Automation and RoboticsAdvanced Life Support Automated RemoteManipulator (ALSARM)The objective of the ALSARMproject is to develop a prototypesystem to take environmentalmeasurements inside theBiomass Production Chamber(BPC) breadboard project (alsoknown as the Controlled EcologicalLife Support System orCELSS) at KSC. The BPC isoperated by the Advanced LifeSupport project office (JJ-G). TheALSARM is performed in conjunctionwith the University ofCentral Florida (UCF). A twosemesterdesign course at UCFresulted in several concepts forthe ALSARM. KSC and UCFdecided on a final concept thatmeets all the system and BPCrequirements. The project iscomplete and operational. PhaseII of the ALSARM project (developmentof an end-effector to takeplant samples remotely) willbegin in late 1998.The BPC consists of twoseparate levels used to growcrops in an almost totally enclosedenvironment. The BPCwill help NASA understand howto grow crops in space for Moonor Mars bases. During the courseof study, technicians have to enterthe chamber to measure environmentalparameters such as airtemperature, infrared temperature,relative humidity, air velocity,and light intensity. Entry ofpersonnel into the BPC disturbsthe environment in several ways.The opening of the chamber dooraccounts for about half the chamberdaily leak rate. The technicianscontaminate the environmentby their respiration, whichexpels carbon dioxide and organicproducts. The mere presenceof technicians can modifythe air flow patterns in the BPC.The environmental measurements,which take about an hour,are performed serially. Also, it isdifficult for people to take measurementsat exactly the samepoints from one type of measurementto another or from one testto another. The ALSARM will bean automated method of takingthese measurements that willeliminate personnel entry, reducethe chamber leak rate, and allowmore consistent measurements.The ALSARM integrates stateof-the-artsystems in control,mobility, manipulation, informationmanagement, and sensortechnologies to perform the BPCenvironmental measurements.The system will be expanded toinclude an end-effector (or tool)on the manipulator to take plantsamples and eventually performother functions such as plantingand harvesting. This end-effectorwill be developed during Phase IIof the ALSARM project thatstarted in August 1998.Key design features of theALSARM include: (1) automatedcontrol via a tether cable, (2) a 3-degree-of-freedom robot manipulator,(3) multiple sensor array, (4)interfaces to existing NASAdatabases, and (5) developmentof an end-effector for plantsampling.ALSARM in the BPCThe accomplishments for 1998include completion of operationaltesting at the BPC, fabrication of a120

Research and Technology 1998replacement sensor array, startup of Phase II (endeffector),and development of a preliminary endeffectordesign.Completion of the preliminary end-effectordesign and fabrication of the replacement sensorarray were the major efforts for the remainder of1998.Key accomplishments and milestones:• August 1993: Project initiated and conceptdesigns evaluated.• June 1994: Final report and design conceptcompleted.• October 1994: Systems requirements reviewcompleted.• October 1994: 30% design review.• November 1994: 60% design review.• November 1994: 90% design review.• December 1994: Final review.• March 1995: Redesign of horizontal telescopingarm started.• August 1995: Redesign of horizontal telescopingarm finished.• October 1997: Fabrication of the ALSARM complete.• December 1997: Laboratory testing of theALSARM complete.• July 1997: Installation of the ALSARM into theBPC.• August 1997 to January 1998: Activation andvalidation testing of the ALSARM.• January to August 1998: Development andfabrication of a replacement end-effector.• Late 1998: Development of the ALSARM endeffector.Contacts: M. Hogue (Michael.Hogue-1@ksc.nasa.gov), MM-G3, (407) 867-1720; W.C. Jones, MM-G3, (407) 867-4181;A.J. Bradley, MM-G3, (407) 867-1720; and Dr. J.C. Sager, JJ-G, (407) 853-5142Participating Organization: University of Central Florida(Dr. R. Johnson)MotorsFlexible ShaftsGripper/CutterALSARM End-Effector Preliminary Design121

Automation and RoboticsAdvanced Payload Transfer MeasurementSystem (APTMS)The objective of this project isto develop a simple, robust,centrally operated, and portablesystem to automatically measureXo, Yo, and Zo offsets betweenthe trunnions and their supportduring payload transfer operationsin the Vertical ProcessingFacility, Orbiter ProcessingFacility, Operations and CheckoutBuilding, and Payload ChangeoutRoom. Each trunnion will beinstrumented and the misalignmentwill be displayed to themove conductor. Future expansioncapabilities include fastcalculation of the next movecommand and closed-loop controlof the operation. Key designfeatures of the APTMS include:• Quick Xo, Yo, and Zo measurementand display of data tomove the conductor• Small and portable transducer• Versatile design for use at theVertical Processing Facility,Orbiter Processing Facility,Operations and CheckoutBuilding, and PayloadChangeout Room• Off-the-shelf optical encodersfor angle measurement• Laptop computer for ease ofportable data analysis anddisplay• Wireless port connectionbetween a laptop and dataacquisition system• Programming capability tocalculate the next move command• First step for payload transferautomation at the VerticalProcessing Facility and PayloadChangeout RoomBenefits of the APTMS include:• Capability enhancements• Reduction of time and cost forpayload transfer• Increase in measurementaccuracy and reliability; reductionof error opportunities• Increase in payload and techniciansafety• Avenue for payload transferautomation of four differentlocationsCommercial applications of theAPTMS include:• Crane operations• Construction• Assembly• Manufacturing• Automotive• AerospaceKey accomplishments and milestones:• Mechanical, electrical, andsoftware system testing hasbeen completed. Furtheradjustments are in work tomeet the positioning requirementsof 0.05 inch at a 6-inchrange.• 1995: Developed prototypeunit.122

Research and Technology 1998APTMS in Operation• 1996: Tested prototype unit and made modifications.• 1997: Started development of production unit, design, and fabrication.• 1998: Completed production unit and tested and implemented modifications to enhanceaccuracy and ease of calibration. Developed a demonstration simulation tool for presentationto customers.Contacts: W.C. Jones (William.Jones-3@ksc.nasa.gov), MM-G3, (407) 867-4181; and E. Lopez Del Castillo andF. Soto Toro, MM-G3, (407) 867-8005123

Automation and RoboticsAutomated Umbilical Mating TechnologyNumerous launch vehicles, planetary systems, and rovers requireumbilical mating for fluid flow and electrical connections. Simple,reliable, autonomous mating is required to make certain missions andsystems feasible (i.e., Mars methane fueled rovers) and to provide lowcost,safe launch operations. The environment for mating (temperature,humidity, dust, cost, weight, and power) varies drastically fromsystem to system. However, a common core technology and numeroussensor and mating techniques are needed to provide low-cost,common solutions for all systems. The technical approach involvesthe following:• Development of a smart umbilical with a reconnect capability (Thisproject will leverage off an existing Small Business InnovationResearch (SBIR) project and additional available hardware.)• Autonomous or remote operationsusing vision systems,force feedback, miniaturizedgas detection, and state-of-theartreal-time control• Umbilical that provides thecapability to connect, disconnect,and reconnect during anypoint in the launch countdownprocess• Investigation of various sensorand mechanism concepts fordifferent mating environmentsSBIR Smart UmbilicalExisting IRB RobotUsed for Flight-SideExcursions124

Research and Technology 1998The benefits to NASA missionsinvolve the following:• Autonomous methane-fueledMars exploration rovers (requiredfor Mars sample return)• Capability to connect, disconnect,and reconnect during anypoint in the countdown processfor the Reuseable LaunchVehicle (RLV), Liquid FlybackBooster (LFBB), and EvolvedExpendable Launch Vehicle(EELV) (Low-cost, high-reliabilityautonomous mating willenhance all future launchvehicles.)• Cheaper, safer launch operations• Increased launch reliabilityCurrently, a Phase II SBIRproject is investigating anddeveloping a highly reliable, safe,and smart automated ground/flight umbilical carrier plate forremote installation and removal.The umbilical plate will containmultiple service connections forcryogenic propellants, pneumatics(gaseous nitrogen and gaseoushydrogen), environmental controlgases, and electrical power anddata. The umbilical will have theability to mate, demate, andremate with little or no humanintervention. Flight side andground side will be demonstratedwith dynamic excursions basedon real-world data.The smart umbilical matingsystem will provide for two fluidconnections and four electricalconnections. After the operatormanually drives the umbilical towithin its alignment area, thevision control system will takeover and drive the umbilical tomate with the flight-side plate.The operator has the option togive the final permission toperform each step in the matingprocess and can interrupt themating process at any time.When the mating process isinterrupted, the umbilical willreturn to the previous safe step inthe mating process or will returnto the home position, dependingon how it is interrupted.After the umbilical plate hasbeen connected and latched to theflight-side plate, the umbilicalsystem goes into a passive mode,whereby it follows the excursionsof the flight side. Then theelectrical and fluid connectionsare verified for leaks and connectivity.The operators will accesssystem controls through thesoftware loaded into the controlconsole computer. From thisconsole, the operator will havecontrol of and feedback from theentire system as well as thecamera view of the vision system.All data acquisition hardware isalso interfaced to this industrialcomputer. Additional designrequirements include:• Compliant self-aligningground-side carrier plate• Traceability to a nonsinglepoint failure design• Real-world dynamic and staticvehicle excursions• Quick and reliable remoteverification of interface integrity• IRB 90 robotic arm to mimicvehicle excursionsKey accomplishments and milestones:• June 1998: Completion of theSBIR mechanical design.• October 1998: Completion ofthe SBIR electrical design.• 1999: Completion of the SBIRautomated umbilical and testand modify to provide fullautomation capability.Contacts: T.C. Lippitt (Thomas.Lippitt-1@ksc.nasa.gov), MM-G3, (407) 867-1720; and W.C. Jones, MM-G3, (407)867-4181125

Automation and RoboticsPayload Ground Handling Mechanism(PGHM) AutomationThe PGHM is located in thePayload Changeout Rooms ofSpace Shuttle Launch Pads A andB at KSC. The PGHM is used toremove or insert the Shuttlepayload from both the orbiterpayload bay and the payloadtransport canister. The PGHMprovides the capability to load/access payloads when the vehicleis at the launch pad. Upgrades toPGHM systems are required toprovide United Space Allianceoperations personnel the capabilityto process vertical payloads ina safer and more efficient environment.The PGHM consists ofthe following mechanisms:• Power X: coarse verticalmotion• Power X Stop Nut: redundantsafety feature of Power X• Power Y: coarse side-to-sidemotion• Payload Support Beam X(PLSB X): fine vertical motion• Payload Support Beam Z(PLSB Z): fine insert andretract motion• Stem Strain: PGHM weightdistribution stability• J-Hooks: X, Y, and Z: very finemotionThe current PGHM designuses pneumatics and manpowerfor axis actuation. Throughautomation, position feedbackcircuits, and the elimination ofhazardous manual drive systems,the proposed upgrades willprovide a safer, more efficientprocessing environment. Theproject scope will be divided intotwo major efforts:1. Automated Control of Mechanisms.The Power X, Power XStop Nut, Power Y, PayloadSupport Beam X, PayloadSupport Beam Z, and StemStrain mechanisms will beautomated using commercialoff-the-shelf electronic controlsystems. Numerous hardwarecriticalfailure points andhuman-intervention-dependentoperations will be eliminated.A centralized controlconsole with a graphical userinterface will be provided forthe PGHM Move Director tocommand operations. Themain objectives are to:• Eliminate the hardware singlefailure points.• Eliminate the operations inwhich human error couldcause hardware damage orhuman injury.• Provide better control andfeedback to the payload MoveDirector and technicians.• Increase the operational efficiencyand reduce the numberof personnel required forpayload transfer.2. J-Hook and Orbiter-to-PayloadPosition Measurement Study.J-hook and orbiter-to- payloadposition measurement requirementswill be detailed and thesystem design approach will bedetermined in a study.Contacts: W.C. Jones (William.Jones-3@ksc.nasa.gov) and A.J. Bradley,MM-G3, (407) 867-4181Participating Organizations: UnitedSpace Alliance and Dynacs EngineeringCo., Inc.126

Research and Technology 1998NTSCADAServerOfficeWorkstationWindows 95/98NTWorkstationGatewayNeuralNetWorkstationTCP/IP100BTFiberWirelessPCWithinternalI/O CardsPCWithPLCSubtiersDH+HMIModbusPassiveBackplanePC(PGHM TestPlatform)HMIEthernetMotionControllerIRDA PortFoundationField BusPLCDirectConnectionTo EthernetSLC5PLC5Ethernet I/ODevice NetWirelessEmbeddedPC ControllerCompressedVideo/AudioPLCPLCWirelessOfficeNodeIntegrated PC-BasedControl PendantMultiplexedVisionIntegrated Operations Development System127

Automation and RoboticsCable and Line Inspection Mechanism (CLIM)Biannual inspections of theseven slide-wire cables usedin the Emergency Egress Systemat both Launch Pads A and Brequire inspection crews tovisually verify the integrity of thecable as the crews are lowereddown the cable in the slide-wirebaskets. Due to the type of cableused as slide-wires (i.e., stainlesssteel), magnetic resonant devicesnormally employed to inspectcables are inadequate. This manintensiveand time-consumingoperation prompted a request tothe Automated Ground SupportSystems Laboratory to develop astand-alone system for automatedcable inspection. In addition, nomethod exists for inspection ofthe lightning cables at eachlaunch pad due to their inaccessibility.The cable failures to be identifiedby the automated system, perthe applicable Operations andMaintenance RequirementsDocument (OMRS File IV), arecharacterized by frayed strands,bird nesting, stretching, andcorrosion. The cable undergoesload testing on a periodic basisand is man rated by weightingthe egress baskets with sandbagsand sending them down thecable. Consequently, this is not atask for the automated system.The inspection teams rely on avisual inspection of the surface ofthe cables with a cursory check ofthe cable diameter using a go/nogogage every 10 feet. The targetedcables were identified tohave an inclination of no morethan 45 degrees, a length ofapproximately 1,200 feet, and adiameter of 1/2 to 3/4 inch.Finally, a prototype unit hadalready been developed for theproject but required testing. Aproduction unit based on theprototype design was needed.control scheme using a radiofrequency control system forradio-controlled airplanes wasemployed. A method of measuringthe cable diameter was found.Finally, a microcomputer tocontrol the unit was used. Due tothe limited accessibility to powerover the distances involved, theunit operates on batteries.The prototype unit was testedon 300 feet of guy wire supportingthe 500-foot weather towernorth of the Vehicle AssemblyBuilding. The guy wire was 3/4inch thick and at an inclination of15 degrees. The unit was operatedon the cable until the distancesrequired for the slide-wireinspections were obtained. Thedata captured from the test wasgraphed for demonstration.Problems were identified andalternate equipment was chosen.Currently, the manufacture of aproduction unit is in process foruse by the customer. A 75-percentdrawing package has been released.Key accomplishments:• 1997: Identified customerrequirements.• 1998: Tested the prototypeunit. Manufactured the productionunit.Key milestone:• 1999: Assemble, test, and turnover the production unit.Contacts: W.C. Jones (William.Jones-3@ksc.nasa.gov), MM-G3, (407) 867-4181; and R.L. Morrison, MM-G3,(407) 867-4156CLIM Cable VideoParticipating Organizations: NASAMM-G3 (R. Morrison, J. Bonner, andM. Hogue), NASA PK-J (K. Nowak),NASA MM-E (J. Richards-Gruendeland L. Parrish), and United SpaceAlliance (G. Hajdaj and M. Olka)128

Research and Technology 1998Prototype Unit on the Test CableLaunch Pad Tower View of the Slide Wires129

Automation and RoboticsThe objective of the OmniBotproject is to develop a hazardousduty mobile base as anadvanced development test bedto research alternate technicalapproaches for remotely controlledoperations in hazardousareas. In addition, this base willbe used to test various automatedumbilical technologies for autonomousmobile vehicles. Inhazardous environments where itis too dangerous to send inunprotected personnel, a mobilebase could be used to performremote inspections, site surveys,and operations.OmniBot Mobile BaseThe OmniBot is driven withfour brushless servomotorsconnected to omnidirectionalwheels (Mechanum). This allowsfor complete 2-degree-of-freedommotion, which results in extremelyhigh maneuverability.The benefit of this motion profilecan truly be appreciated when thevehicle is operated in a teleoperationalmode.Currently the vehicle can becontrolled with a radio frequency(RF) control box or with ahardwired joystick. With thevideo transmission gear installed,teleoperation is possible up to adistance of 1,800 feet.The next phase in the projectis the construction of anoperator’s control station, asensor package, and manipulatorsystems.Key accomplishments and milestones:• January 1997: Construction ofthe motion base.• June 1997: Testing of themotion base and control system.• March 1998: Construction ofthe RF control system.• August 1998: Selection/procurement of the multitaskingsystem.• September 1998: Installation ofthe video RF gear.Contacts: T.C. Lippitt (Thomas.Lippitt-1@ksc.nasa.gov) and W.C. Jones, MM-G3, (407) 867-4181OmniBot Mobile BaseCloseup of Omni (Mechanum) Wheels130

Research and Technology 1998Electro-Mechanical ActuatorThe objective of the Electro-Mechanical Actuator(EMA) project is to evaluate and demonstratethe viability of electro-mechanical actuators toreplace pneumatic actuation for use in launchprocessing ground support equipment (GSE) atKSC. The current pneumatic actuation systems,such as the cryogenic fuel and oxidizer systems,firex systems, sound suppression system, etc.,require high maintenance and the components arebecoming old and obsolete. These systems arelocated at the launch pads and are exposed to therigors of launch and the high humidity and saltyseaside environment. Use of EMA’s has the potentialto reduce the complexity and number of componentsrequired by as much as 80 percent.Commericial off-the-shelf electro-mechanical actuatorsare being evaluated, and methods of providinghigh reliability through redundancy are beingaddressed. Higher position accuracy and repeatabilityare also potential benefits from the use ofEMA’s.The EMA system consists of one electromechanicalactuator controlled by two program-mable logic controllers (PLC’s) and two servodrivesin a parallel configuration for highly reliableoperation. Commercial use of single-string controlusing PLC’s and servo-drives for EMA’s has proventhese system components to be highly reliable,accurate, and economical. Once studied and provenfor dual-control redundancy, the concept couldprovide the same benefits for critical systems.Key accomplishments and milestones:• April 1998: Design and layout of the EMA testplan.• June 1998: Procurement and mounting of AllenBradley PLC’s and servo-drives.• September 1998: Procurement of Class I, DivisionI, electro-mechanical actuators manufactured byExlar Corporation.• January 1999: Testing and evaluation of EMAconfigurations, operating characteristics, andreliability and repeatability.Contacts: W.C. Jones (William.Jones-3@ksc.nasa.gov), MM-G3, (407) 867-4181; and T.H. Miller, MM-G3, (407) 867-4156Participating Organizations: NASA Process EngineeringDirectorate and United Space Alliance131

Automation and RoboticsSolid Rocket Motor (SRM) StackingEnhancement Tool (SSET)The NASA Automated GroundSupport Systems Lab (MM-G3) of the Engineering DevelopmentDirectorate is developingthe SSET, a mobile data acquisitionsystem used to monitor theSpace Shuttle solid rocket motorstacking process in the VehicleAssembly Building (VAB) at KSC.Four SRM segments are matedtogether to form a solid rocketbooster, with two completedboosters used for each SpaceShuttle. SRM segments areattached to a four-point liftingbeam, a device that can vary theload of each of its attachmentpoints and modify the segmentshape to match that of its partner.The entire assembly is thenLifting Beamhoisted by a crane and loweredonto the SRB under construction.The segment junction points, orfield joints, are critical interconnectionswhose failure couldcause a catastrophe.The stacking process takesmany hours and is manpowerintensive, so delays due to systemfailures are costly. The SSETreplaces and combines the functionsof two antiquated systemsalready in use, the Temposonicsmeasurement system and thelifting beam load panel. TheTemposonics measurementsystem is composed of four onedimensional(1D) sensors (whichare located at 90-degree intervalsbetween the two segments) and adata acquisition computer system(used to display and record thenumerical measurements). Themeasurements are used to determinethe distance to mate, levelness,and lowering rate. Thelifting beam load panel uses sixstrain-gage-type load cells locatedin the SRM lifting beam to measurethe loads and levelnessforces of the suspended segment.Currently, no data recording isavailable for the loads.The SSET provides currenttechnology data acquisitionequipment to measure the existingsensors. Some benefits of theSSET are:• A single display unit reducesthe number of equipment items(figure 1).• The information is displayedon an intuitive graphical userinterface and is easy to interpret(figure 2).DTM SensorsSSET Panel• All measurement data will berecorded.• The modular design allows forsystem modifications andupdates.Connector PanelFigure 1. SRM Stacking Enhancement ToolControlPanelUPSPowerPlugGroundLug• The onboard uninterruptiblepower supply (UPS) guardsagainst data loss due to powerfailure.• Advisory functions helpoperators maintain segmentlevelness.• Built-in test ports allow foreasy troubleshooting.132

Research and Technology 1998Figure 2. Graphical User Interface• All operator events and configuration values are logged for future reference.• Up to 1 hour of real-time data is maintained for review during stacking.• Data review software is provided for posttest analysis.Three production units are fabricated and undergoing certification at KSC. SSEToperational readiness is scheduled for early 1999.Key milestones:• Completed proof-of-concept shadowing operation of an SRM stacking and destacking.• Completed electromagnetic interference susceptibility tests.• Completed the initial inert segment stacking operation.• Scheduled the design certification review and operations turnover for 1999.Contacts: W.C. Jones (William.Jones-3@ksc.nasa.gov) and A.J. Bradley, MM-G3, (407) 867-4181Participating Organizations: Dynacs Engineering Co., Inc., NASA PK-H, and United Space Alliance133/134

Research and Technology 1998Electronics andInstrumentationThe Electronics and InstrumentationTechnology program at the John F.Kennedy Space Center (KSC) supportsthe development of advancedelectronic technologies that enhance safetyand quality, decrease launch vehicle andpayload ground processing time and cost,and improve process automation. Theprogram includes the application ofapplied physics and chemistry and electricaland electronic engineering, particularlyin the areas of sensors, data acquisitionand transmission, advanced audiosystems, digital computer-controlledvideo, contamination and gas detectioninstrumentation, field inspection andnondestructive testing, and circuit monitoringinstrumentation. The near-termprogram focuses on Space Shuttle, payloads,and Space Station ground processingenhancement by developing instrumentsin monitoring, testing, and vehicleprocessing. The long-term program isdeveloping technology for support offuture space vehicles, payloads, andlaunch systems by advancing the state ofthe art in launch vehicle and payloadprocessing electronics and instrumentationto reduce costs and improve safety.135

Electronics and InstrumentationSpace Shuttle Integrated Vehicle HealthManagement (IVHM) Flight ExperimentThe IVHM Human Explorationand Development of Space(HEDS) Technology Demonstration(IVHM HTD) flight experimentwas the first KSC designedand built payload. Its purposewas to demonstrate competingmodern, off-the-shelf sensingtechnologies in an operationalenvironment to make informeddesign decisions for the eventualorbiter upgrade IVHM. There arethree objectives of IVHM:1. More autonomous operation inflight and on the ground,which translates to reducedwork load on the groundcontroller team. Near Earthspace operations provide theluxury of having a groundteam evaluate vehicle data tomake real-time decisions. On aMars mission for example,there is a 40-minute time delayto send and receive a message.Therefore, future vehicles willrequire more autonomouscapabilities.2. Reduced ground processing ofreusable vehicles due to increasedperformance of systemhealth checks in flight ratherthan back on the ground.3. Enhanced vehicle safety due tothe ability to monitor systemhealth even inside the harshenvironment of an enginecombustion chamber as well asprediction of pending failures.The “integrated” piece ofIVHM is the total integration offlight and ground IVHM elements.The four elements offlight IVHM are advanced lightweight/low-powersensors,distributed data acquisitionarchitecture, data processing, andmass storage. The three elementsof ground IVHM are evolvedcontrol room architectures,advanced applications, andautomated ground processingsystems. While incorporation ofan IVHM architecture into a newvehicle is a complex process initself, implementation of IVHMinto the Space Shuttle programmust deal with additional considerationssuch as not impacting theflight manifest, cost/paybackanalysis, evaluation of militaryand commercial off-the-shelf(COTS) components, and vehicleretrofit installation considerations.The first IVHM HTDflight experiment was successfullyflown on Discovery on STS-95 from October 29 to November7, 1998. The second IVHM HTDflight experiment will re-fly allelements as well as additionalsensing systems on STS-96 with aplanned launch date of May 13,1999.During cryogenic propellantloading in the terminal launchcountdown, the IVHM datastream was routed out of theorbiter’s T-0 umbilical for transmission,processing, and viewingin the Launch Control Center(LCC) via a new Ethernet networkinstalled in the MobileLauncher Platform, using existingfiber-optic lines connecting thelaunch pad with the LCC andusing the new Checkout andLaunch Control System (CLCS)elements. The IVHM processorautonomously began recordingdata at T-10 seconds prior to136

Research and Technology 1998Space Shuttle main engine start.Data was recorded during ascentand on-orbit during daily 1-hoursnap-shot periods. The processorwas dumped to the CLCS afterthe orbiter landed and was rolledinto its Orbiter Processing Facilitybay. Flight data evaluation of thefirst flight experiment is underway,and a preliminary assessmentis that the system had 100percent performance. The followinglists contain the demonstratedtechnologies and the organizationsresponsible for their development.IVHM HTD-1• Micro-electromechanicalsystems (MEMS) hydrogendetection – LeRC, Case WesternReserve University/Makel(G. Hunter)• Galvanic cell oxygen detection– KSC• Main propulsion system (MPS)vacuum-jacketed (VJ) linepressure sensing – KSC• RS485 smart sensor technologyfor hydrogen detection, oxygendetection, and VJ pressure –KSC• MPS helium leak detectionusing thermal flow technology– KSC• Integration/flight certificationtesting (thermal, vacuum,vibration, radiation, EMI, andEMC) of COTS conductioncooled VME bus architecture,flash memory, PowerPC processor,IRIG interface card, andall sensors – KSC• Data processing softwarearchitecture (scheduler, internalhealth checks, and data acquisition)using VxWorks – KSC• Ethernet ground data processingsystem – KSCIVHM HTD-2• Hydrogen detection usingfiber-optic Bragg-Gratingtechnology – LaRC and Universityof Maryland (K. Vipavetz)• Structural strain and temperaturedetermination using fiberopticBragg-Grating technology– Rockwell Science Center (B.Christian)• Distributed data processingusing X-33 Remote HealthNode technology – LockheedMartin, Sanders Division (R.Garbos)• Fiber Distributed Data Interface(FDDI) technology –Hampshire Vanguard TechnologyAssociates (T. Hardy)• Space Shuttle Main Engine(SSME) pump vibration monitoringsystem with digitalsignal processing technology –MSFC (T. Fiorucci)Additional information isavailable on the World Wide Webat: http://www.ksc.nasa.gov/shuttle/upgrades/ksc/ivhm/data depot/ivhmhome.htmContacts: J. Fox (Jack.Fox-1@ksc.nasa.gov), R. Hanson, and S. Wilson, AA-D,(407) 867-2001Vacuum-Jacketed Line Smart SensorH 2 and O 2 Smart Sensors137

Electronics and InstrumentationOrbiter Jack and Leveling OperationsAfter landing, the orbiter istowed into the Orbiter ProcessingFacility (OPF) and positionedso the pair of nose landinggear (NLG) tires and each pair ofmain landing gear (MLG) tires arecentered on a floor lift. The liftunder the NLG tires raises thenose of the orbiter until the pitchof the orbiter is horizontal; thenthe three lifts simultaneouslyraise the orbiter to a specifiedheight (the maintenance height)while maintaining the horizontalpitch. The proper maintenanceheight of the orbiter is criticalbecause the surrounding facilityplatforms are designed for thisheight. Once at the maintenanceheight, the orbiter jacks areinstalled and the lifts are loweredto the ground. During a typicalorbiter processing flow, the rearsupport of the orbiter is transferredfrom the aft jacks to theMLG floor lifts and then backagain while the forward jacksremain attached.These operations require aheight measurement accuracy of±1/4 inch. This is currentlyachieved with a set of calibratedmeasuring sticks to determine theheight at each of the four jackattach points. The disadvantagesto this measuring technique are(1) the sticks are long and thinand technicians have difficultymaintaining them vertical to theground, (2) the distance readvaries with the force the userexerts when pressing the rodagainst the orbiter, and (3) thistechnique is time consuming anduses a significant number ofpeople. Furthermore, the longsticks are awkward to handle andthere is potential for orbiter tiledamage when the top of the stickis raised to vertical. Due to thesedifficulties, a replacement to themeasuring sticks is desired.The key to solving this problemis the use of the Leica laserrangefinder. This device allows auser to aim a laser beam at atarget and read the distance tothat target to within ±1/8 inchfrom distances between 5 and 200feet. A system (see figure 1) wasdeveloped whereby four of theserangefinders were used, two tomeasure the height from the floorto the aft jack attach points andtwo to measure the height fromthe floor to the forward jackattach points. All four communicatetheir results to a centralcomputer on a desk located to theleft side of the orbiter midbody.Each of the Leica units is heldin a vertical orientation by analuminum framework. Theelectrical connection to the Leicarangefinder provides RS-232communication (9,600 baud) andpower. The Leica rangefinderand its framework have beenattached to a triangular base witha bubble level, two tilt adjustmentscrews, and a fixed foot. The tiltadjustment feature allows compensationfor small variations inthe flatness of the floor of the OPFto ensure the laser beam pointsnear vertical.Figure 1. Four Leica Laser RangefindersThe signals from the rangefindersare brought back to thecentral computer. The softwarewas written in LabView, whichallows for direct control of an138

Research and Technology 1998Figure 2. Computer Display of Leica Laser Rangefinder ResultsRS-232 as well as the Leica rangefinders. An imageof the orbiter is displayed with four bars (see figure2; note that no bars are visible) reaching from belowthe orbiter up to the jack attach points. The heightin inches from the floor to each jack attach point isshown and the bar is color coded to indicate thestatus of the measurement. Typically the bars arered if the distance is an inch or more too low, areyellow if the distance is within 1-1/4 inch too low,green if the distance is within 1/4 inch of the desireddistance, and flashing red if the distance ismore than 1/4 inch too high.If a Leica rangefinder returns an error conditionto the LabView software or if it does not respond atall, the software displays an error condition andcounts the errors. It takes less than 3 seconds typicallyfor all four Leica rangefinders to perform adistance measurement and for the software toreceive and display these numbers. If, for somereason, the software detects a problem with aspecific Leica rangefinder, it displays a “Data DropOut” message in the error status window and doesnot display the distance data.A fifth mounted Leica rangefinder with fullcabling was provided as a spare. All five Leicasystems were fabricated so they are within a fewhundredths of an inch of each other in height andcan be interchanged.Contact: C.B. Mizell (Carolyn.Mizell-1@ksc.nasa.gov), MM-H-A, (407) 867-7705Participating Organizations: United Space Alliance(M. McClure), PK-H (C. Davis), and Dynacs EngineeringCo., Inc. (B. Burns, W.D. Haskell, T.J. Opalka, J.D. Polk, andR.C. Youngquist)139

Electronics and InstrumentationLeak Detection and VisualizationUsing Laser ShearographyThere are currently over 12techniques used to detect andlocate leaks in the various fluidsystems that are part of bothground and flight equipment inthe Space Shuttle program. Oftentimes, detection and location arecarried out by completely separatemethods that add both timeand cost to the testing. A “fullfield” method for detecting,locating, and visualizing leakswas desired, and laser shearographyhas shown promise inthis respect.Laser shearography is aninterferometric technique, meaningit is sensitive to constructiveand destructive interference fromphase differences in coherentlight. “Shearing” optics are usedto image multiple points of alaser-illuminated object onto asingle picture element or pixel. Ina real-time laser shearographysystem, like the one used in thisinvestigation, the phase informationat these points is collected bya video camera pixel array. At thebeginning of a test, an initialvideo frame (called the referenceframe) is captured and fromwhich all subsequent live framesare subtracted. Differences,caused by phase changes, betweenthe reference frame and thelive frame are displayed in liveshear images on a video monitor.Any change in the phase relationmeasured at an individual pixel,whether due to a path lengthchange of some of the lightinitially imaged on that pixel ordue to the bending of light causingmore or fewer object points tobe imaged onto that pixel, showsup in the live shear image as avariation in gray level. Lasershearography is, thereby, wellsuited to locate and measure veryslight out-of-plane displacementsor, as in this case, to locate substancesthat change the index ofrefraction in the object space.Two captured images of leaksare shown in the figures. Figure 1shows a very slight leak from anair duster can that is otherwiseinvisible to the naked eye. Theair from the can, which is colderand denser than the ambient air,can be seen to be flowing downwardin the image. Figure 2shows a leak from a calibratedhelium leak system of 2.8 x 10 -3c 3 /s at 1 atmosphere. In thisimage, the helium (which islighter than air) can be seen to beflowing upward.What appears as two leaks ineach of these images is actually asingle leak and its “shadow.” Thelaser illumination source waslocated approximately 1 inchabove the camera, which explainsthe shadow of the leak fixtureseen just below the actual leakfixture. The leak “shadow” wasproduced in a similar way. Lightfrom the laser had two opportunitiesto pass through and beaffected by the leak – once on itsway from the laser source to thebackground (located approximately3 inches away) and onceon its way from the backgroundto the camera. Since the laser waslocated above the camera, theupper indication is due to lightpassing through the leak afterbeing reflected off the background.The lower indication isdue to light passing through theleak before reaching the background.Where the two leakindications overlap is where lightpassed through the leak in bothdirections.It was determined that heliumleaks as small as 10 -3 c 3 /s at 1atmosphere could be detectedwithout additional image processing.Leaks were much moreapparent in the live video as oftenthe motion of the leak helped setit apart from background noise.Better results were obtained bycapturing reference frames atshort, regular intervals whichhelped eliminate the slow, constantincrease in noise caused byslight changes in the surroundingenvironment. Future plans forleak detection with laser shearographyinclude a probability ofdetection study of helium leaks inair and in a vacuum and studiesof other types of leaks in severaldifferent environments.Contact: J.D. Collins (David.Collins-1@ksc.nasa.gov), MM-G, (407) 867-7069Participating Organizations: I-NET,Inc. (S.M. Gleman) and DynacsEngineering Co., Inc. (J. Donahue, S.W.Thayer, and D.L. Thompson)140

Research and Technology 1998Figure 1. Air Duster Can LeakFigure 2. Helium Leak 2.8 x 10 -3 c 3 at 1 Atmosphere141

Electronics and InstrumentationSupport of the Linear AerospikeSR-71 Experiment (LASRE)KSC has been launching vehiclesfor almost 40 years.The knowledge gained over thistime has proven to be of use toother NASA centers and supportcontractors. One such area is thatof checking vehicles for fuel leaksbefore launch. Recently, personnelfrom KSC were requested toassist Dryden Flight ResearchCenter (DFRC) personnel in theireffort to determine if the LASREwas safe for flight. Because theengine used gaseous hydrogenand liquid oxygen for the fueland oxidizer, the experimentcould not be flown until it wasdemonstrated to be free of leaks.KSC was contacted to assistDFRC because of difficultiesarising while trying to leak checkthe engine.The LASRE test plan includeda small half-span model of theX-33 Aerospike Engine mountedonto an SR-71 aircraft. Theengine was then to be flown to analtitude and test-fired. Theseexperiments would answerquestions about the performanceof the engine as well as how areusable launch vehicle’s engineplume would affect the aerodynamicsof its lifting body shape atspecific altitudes and speeds.However, before the engine couldbe fired at altitude, it had to beshown to be free of fuel andoxidizer leaks.In response to the request forsupport, KSC sent a mass-spectrometer-basedsystem, namelythe Interim-Hydrogen UmbilicalMass Spectrometer (I-HUMS),and personnel to DFRC to supportthe leak tests. I-HUMS wasdeveloped during the summer of1990 to help find the leaks on theorbiters for flights STS-35 andSTS-38. Helium and hydrogenFigure 1. I-HUMS Under the SR-71 for Leak Checkswere the only gas species monitoredfor these experiments, eventhough the I-HUMS can monitoradditional gases. This reportcovers one of the two tests supportedby KSC. This test wasdeemed the most valuable.Figure 1 shows the I-HUMSattached to the LASRE during acold firing of the engine.The leak test performed onthe LASRE was based on theShuttle Aft Helium SignatureLeak Test (V1202), which iscurrently performed before eachlaunch. The entire system wascharacterized because the LASREhad no history or baseline. Thetest required the I-HUMS tomonitor helium at one samplelocation; the I-HUMS can supportup to 16 sample locations. Becausethe purge was not a simplein/out model, it also was characterized.This is due to the factthat the feed system is distributedthroughout the purged environment(see figure 2). Venting isthrough many tiny holes throughoutthe skin of the test article.Both of these characteristics madethe purge path unknown.The I-HUMS was used tomonitor the purge of the LASREwhile a calibrated helium leakrate was injected into multiplelocations in the test article. Theinjection of a known leak rate intoa known purge was used tocharacterize the engine purge.This characterization was subsequentlyused to determine theminimum signal that would bedetected for a given engine leak.A second calibrated helium leakrate was injected to enablequantitation of any engine leak.142

Research and Technology 1998Purge SourcesEngineH 2 O Tanks, GH 2 TanksCanoeSample of the HeInjection LocationsMonitoringLocationFigure 2. Layout of LASRE Leak CheckingAfter the engine purge wascharacterized, the engine waspressurized with helium. TheI-HUMS was then used to monitorthe helium levels in the purgeuntil a level reading was reached.The helium pressure in the enginewas then increased to a higherpressure. The helium levels inthe purge were again monitoreduntil a stable reading wasreached. The recorded valueswere used to predict the operatingleak rate. The planned operatingtime of the engine duringaltitude tests was extremely short,less than 15 seconds, so that onlya fraction of the calculated leakrate would be introduced into thechamber during an actual flight.These tests demonstrated thatKSC has the knowledge andcapabilities to help solve manyproblems at other centers. Afurther demonstration of theflexibility of the personnel andequipment at KSC is the fact thatthey will be used to support theX-33 launches.Contacts: R.J. Beil (Robert.Beil-1@ksc.nasa.gov), PK-G, (407) 861-3944;and F.W. Adams, MM-G2, (407) 867-4449Participating Organizations: DrydenFlight Research Center (N. Hass) andDynacs Engineering Co., Inc. (T.P.Griffin and G.R. Naylor)143

Electronics and InstrumentationFerroelectric Camera for Infrared Fire ImagingInfrared cameras are currentlyused at the launch pads tomonitor hydrogen flow lines forfires. This is necessary becausehydrogen fires, like natural gasfires, emit very little visibleradiation and are virtually invisibleunder daylight conditions tothe human eye or to normalsilicon-based charge-coupleddevice (CCD) cameras. Thecurrently used infrared camerasare deteriorating and the manufacturer,Insight Vision, has goneout of business, resulting inexcessive maintenance costs andeventually, as spare parts run out,the loss of this capability. Inorder to deal with this problem, itwas decided to replace the oldinfrared cameras with new, stateof-the-artcameras. A low-costcamera was located that appearedto provide adequateinfrared images. This camera, aPalm IR 250 ferroelectric device,is popular as a nighttime peoplelocator used by law enforcementgroups and the Coast Guard. It isrugged, does not require cooling,and provides images in the 8- to12-micron region of the spectrum.One of these cameras was purchasedand configured for fieldoperation at the launch pad withthe goal to produce an imageadequate to meet the monitoringneeds of operations personnel.Before purchasing the Palm IR250 infrared camera, severalversions were brought to KSC forfield testing. They producedgood images of the Shuttle on thepad from inside the perimeterfence and easily imaged hydrogenfire at the flame stack. Astandard hydrogen fire (about a1-foot-high flame) was set up atthe fire training facility and wasimaged from several distancesagainst a variety of backgrounds.In all cases, the images of the firestood out clearly and the performancewas acceptable to operationspersonnel. One camerawas aimed into the sun to see ifthe camera was damaged by abright exposure such as it wouldsee during a launch. The camerabecame saturated but recoveredquickly with no apparent damage.Based on these successfuldemonstrations, a Raytheon TIPalm IR 250 infrared camera wasprocured for the Optical InstrumentationLaboratory to useduring the STS-91 external tank(ET) tanking test and launch(May 1998).In summary, the camera wasstrapped down to a plate with apower supply and microcontrollerstrapped down behind it. Thisplate sits on a set of six vibrationisolators attached to a slide railassembly welded to the backplate(see the photo). Standard operationaltelevision (OTV) connectorswere placed on the backplatewith the pan-and-tilt signals fedthrough the camera housing to apan-and-tilt connector. A germaniumwindow was mounted inthe frontplate, allowing thecamera to look out of the housingin the 8- to 12-micron region. ABlue Earth Research microcontrollerwas programmed to allow theOTV analog voltage levels to beconverted into RS-232 commandsto control the camera. Gain, level,auto/manual switching, andfocus were provided as operatorcontrollablefeatures through thiscommunication system. Significanteffort went into ensuring thehousing was well sealed so itcould be pressurized to a fewpounds per square inch in thefield and would hold this pressurefor a period of days.United Space Alliance testedand verified the performance ofthe completely housed andconfigured camera system, andthe system was installed onLaunch Pad 39A. The videosignal was sent through theLaunch Control Complex OTVrouting system.Initially, the camera wasaimed at a variety of objectsaround the pad and producedgood infrared images; however inthe cool early morning hours, thecamera showed a dark imagewith minimal imaging. This wasexplained as a limitation in thesensitivity of the camera. Earliertesting had not disclosed thisbecause the testing was doneduring warm daytime conditions.During a cool night when theambient temperature dropped,the camera had trouble seeingbackground objects and produceda dark image. This conditionwould make it difficult to locatethe position of a fire if backgroundobjects could not be seen.It was decided, however, that thePalm IR camera would be left inthe field for the ET tanking testand the launch.144

Research and Technology 1998The camera performed well during the tests. Itproduced good infrared images of the orbiter beforeand during launch and was able to remain runningeven during launch. This was important becausethe existing Insight Vision cameras must be shutteredduring actual launch, which prevented monitoringthe area for fires during a short but criticalperiod. The Palm IR camera actually spotted a fireafter the launch; a patch of dried grass near the padhad caught fire during launch. Shortly after launch,the camera was brought back to the Optical InstrumentationLaboratory, and the decision was madethat a better (i.e., lower detection temperature)camera was required for fire imaging at the launchpad. Work is ongoing to choose such a camera andto procure one or more for field trials during 1999.Contact: C.B. Mizell (Carolyn.Mizell-1@ksc.nasa.gov),MM-H-A, (407) 867-7705Participating Organizations: United Space Alliance(D. Carter and D. Exley), MM-J1-A (L. Hand), PK-G(K. Brock), and Dynacs Engineering Co., Inc. (R.B. Cox,W.D. Haskell, F. Lorenzo-Luaces, and R.C. Youngquist)145

Electronics and Instrumentation6U VME Universal Signal Conditioning Amplifier (USCA)Interface ModuleThe objective of this project is todevelop a 6U VME bus cardand software to interface with theUSCA’s. The combination of the6U VME module and the hardwarewill allow users to developcustomized data acquisitionsolutions using USCA’s andcommercial off-the-shelf 6U VMEhardware.The module will receive serialdata streams from the USCA’s,will decode and buffer the data,and will transport the data over aVME bus for data archival andtransmission. The module willalso be used to communicatecommands to and receive statusinformation from USCA’s in thefield.Key accomplishments:• A low-speed prototype wasdesigned and built.• The development of aVXWorks driver for the cardwas started.Key milestone:• Complete the development ofthe 6U VME interface moduleand supporting hardware.Contact: C.M. Ihlefeld (Curtis.Ihlefeld-1@ksc.nasa.gov), MM-G2-A, (407) 867-6747Participating Organization: DynacsEngineering Co., Inc. (P.J. Medelius andJ.J. Henderson)146

Research and Technology 1998Medical Aeronautical Communications SystemKSC relies upon Department ofDefense helicopters to supportsearch, rescue, and medevacfor flight crew and personnelsupporting Shuttle programlaunches and landings. Thesehelicopters are normally configuredfor military combat missionsand must be reconfigured rapidlyto support the NASA mission onlaunch and landing days. Communicationsare necessary withKSC medical, fire, safety, andrescue radio nets as well ashospital emergency roomsthroughout the state. However,military communications systemsaboard these helicopters are notcompatible.The Biomedical Laboratoryhas designed, fabricated, and putinto place a Medical AeronauticalCommunications System thatprovides (1) VHF-FM/simplexradio communications capabilityon all KSC radio nets; (2) UHF-FM/duplex communications tohospitals, the Launch ControlCenter (LCC) firing room, and theclinic; and (3) a seven-stationprivate/helicopter intercomsystem. This allows the physicianaboard the helicopter to talk withthe two assigned pararescuemenas well as the two patients. Theflight engineer also has access tothe system, and a spare access isprovided. The system has beenprogrammed to permit communicationson U.S. Coast Guardfrequencies for those helicoptersproviding Range Safety clearingof shipping assets in the solidrocket booster drop zones at sea.This system is battery operatedand interfaces the helicopterintercom system with impedancethat makes it appear as a singleheadset. A unique externalantenna system is provided thatexchanges the standard hoisthook access door with a similarfunctioning structure whichexposes VHF and UHF antennasout of the bottom fuselage of theairframe. Testing and missionusage thus far aboard four HH-60G Blackhawk helicopters haveshown the system to be a significantimprovement over thepreviously disclosed portablesystem carried aboard thesehelicopters.Contacts: D.F. Doerr (Don.Doerr-1@ksc.nasa.gov), JJ-3, (407) 867-3152;and H.E. Reed, JJ-3-B, (407) 867-7551147

Electronics and InstrumentationPortable Magnetic Field Sensor forMeasuring Lightning EffectsThe objective of this project wasto design a reliable sensor formeasuring magnetic fields insidethe Payload Changeout Room(PCR) on each launch pad. Informationobtained by the sensorwill be used to determine themagnitude of the voltages inducedinto cables by the magneticfield generated by a lightningstrike. Depending on the distanceto the lightning strike andthe area covered by the conductors,the induced voltage canreach several thousand volts for aduration of close to 100 microseconds.A complete magnetic fieldmeasurement requires the use ofthree orthogonally placed antennas.This requires the use of threedata conditioning, digitization,and storage channels. It is importantto keep the total powerconsumption to a minimum inorder to extend the lifetime of thebatteries in the sensor.The sensor was designed withthree data conditioning anddigitization channels, with onlythe first channel continuouslypowered up. Under normaloperating conditions, data fromthe three orthogonal antennas issampled sequentially at a 1 megasample per second (MS/s) rate.Upon detection of a nearbylightning strike, the followingactions take place:1. The data from the preceding100 microseconds is stored.2. The power to digitizationchannels 2 and 3 is restored.3. The multiplexer stops alternatingamong the three channelsand connects each antenna toeach digitization channel.4. The clock signal for all threedigitizers is set to 30 megahertz.5. Data is acquired for an additional100 microseconds at a 30-MS/s rate.6. The power to channels 2 and 3is removed.The data preceding the triggeris sampled at 1 MS/s, and thedata following the trigger issampled at 30 MS/s. The latencybetween the onset of the triggerand the sampling clock switch isin the order of a fraction of amicrosecond. This operationresults in most of the informationbeing sampled at the fast rate,thus preserving the data integrity.Since the sensor is never put intoa “sleep” mode, even magneticfields from a first lightning strikecan be acquired. A significantreduction in power consumptionis achieved by powering up onlyone digitizing channel and multiplexingall three measurementsthrough that channel and digitizingthe measurements at a reducedsampling rate.148

Research and Technology 1998Key accomplishment:• The circuit schematic design was completed.Key milestone:• Continue monitoring induced magneticfields inside the PCR.Contact: C.M. Ihlefeld (Curtis.Ihlefeld-1@ksc.nasa.gov), MM-G2-A, (407) 867-6747Participating Organization: Dynacs EngineeringCo., Inc. (P.J. Medelius)149

Electronics and InstrumentationInline Gas Analyzer for Cryogenic HydrogenAprototype inline gas analyzer(IGA) for cryogenic hydrogenwas designed, constructed,tested, and temporarily installedat the hydrogen flare stack onLaunch Pad 39B. NASA’s intentis to use the IGA system to reducethe man-hour requirements andmaterial costs of vehicle preparationsfor cryogenic fuel loadingand safing during and after SpaceShuttle launch operations. Withthe IGA system, measurements ofthe cryogenic operations can bemonitored from a remote, safelocation during hazardous operations.The current method fordoing these measurements is totake a melon sample for each testpoint and analyze it in the laboratoryusing a mass spectrometerand manual field verification ofgas concentrations. If the proto-type program is successful, thefinal design will be permanentlyinstalled at the hydrogen flarestack, the Mobile LauncherPlatform (MLP) liquid hydrogen(LH 2) high point bleed (backporch), and the Fixed ServiceStructure (FSS) gaseous hydrogen(GH 2) vent line at Launch Pads39A and 39B at KSC. The IGAcontains hydrogen, oxygen, andwater sensors to monitor criticalconcentrations of each of thesematerials. The flow path of thesample gas is from the hydrogencryogenic line through the IGAand back to the cryogenic line(see figure 1). In addition to theconcentration data for hydrogen,oxygen, and water, the systemprovides calibration parameters,the ability to recalibrate thesensors, flow rates throughsensors, the temperature andpressure of the sample gas, anderror data for essential components.The following are generalcharacteristics of the IGA:1. The hydrogen sensor canmeasure the concentration ofhydrogen at ±1 percent fullscale over the range of 0 to 10percent. It can operate over thetemperate range from -10 to 60degrees Celsius (°C) and canwithstand the sound andvibration conditions of aShuttle launch.2. The oxygen sensor can measurethe concentration ofoxygen at ±1 percent full scaleand has a range of 0 to 2 percent.It can operate over thetemperature range from -10 to40 °C and be able to withstandthe sound and vibration conditionsof a Shuttle launch.HydrogenCryogenicLineV6CVV2V3V4Flow 1Flow 2H 2O 23. The humidity sensor canmeasure the concentration ofwater at 125 ±10 parts permillion (ppm) and has a rangefrom 125 ppm to 4 percent. Itcan operate over the temperaturerange from -10 to 40 °Cand withstand the sound andvibration conditions of aShuttle launch.SV SV Te PrV1PumpN 2CalV5Figure 1. Inline Gas AnalyzerFlow 3H 2 OV1 Isolation ValveV2 Back Pressure ValveV3 H 2 Flow Control ValveV4 O 2 Flow Control ValveFlowmeters 1, 2, 3SV 1 Helium ZeroSV 2 CALA microcomputer acquires thedata from the sensors and formatsthe data in a manner suitable fortransmission over a serial dataline. In addition, provisions aremade to allow for control ofsolenoid valves from a remoteterminal via the serial data line orlocally from the microcomputerusing pushbuttons. The microcomputerprovides 12-bit analog150

Research and Technology 1998Figure 2. Inline Gas Analyzer With the Moisture, Hydrogen, and Oxygen Analyzerinputs, digital inputs, and digital outputs capable of driving the solenoid valves. The softwareallows the sensor data to be formatted and the controls and valve talkbacks to be processed anddisplays the results. The software also provides control via the serial port, which mimics thefunctions of the buttons and provides diagnostic functions. Figure 2 shows the installation ofthe inline gas sensor at the hydrogen flare stack at Launch Pad 39B.Key accomplishments:• A prototype IGA was designed, constructed, tested, and temporarily installed at the hydrogenflare stack at Launch Pad 39B.• The IGA was successfully used to monitor a storage tank loading operation and found transientsin moisture and oxygen previously unknown.Contacts: R.C. Young (Rebecca.Young-1@ksc.nasa.gov) and D.E. Lueck, MM-G2, (407) 867-4439Participating Organization: Dynacs Engineering Co., Inc. (C.F. Parrish, C.J. Schwindt, S.J. Klinko, and T.R.Hodge)151

Electronics and InstrumentationOrbiter SideSpace Shuttle Orbiter toExternal Tank Mating ToolDuring Space Shuttle processing, the orbiter is joined to theexternal tank (ET) in a processcalled mating. This takes placewith both the orbiter and ET inthe vertical position. Two matingfixtures, located at the aft end ofthe orbiter and ET, are used in themating process. These fixturesare composed of ball-and-sockettypejoints with the ball ends onthe ET side and the socket receptacleson the orbiter side (seefigure 1). During mating, theorbiter is suspended by crane andslowly brought into contact withthe fixed ET. Once the two are incontact, bolts are attachedthrough the ball-and-socket jointto secure the orbiter to the ET.The mating operation iscurrently accomplished usingcaliper and eye-ball measurementsin an iterative approach,which carefully brings the orbiterBolt Clearance HoleFigure 1. Mating FixturesET Sideinto contact with the ET. Theorbiter is initially positioned atapproximately the correct heightand then slowly moved towardsthe ET. As the orbiter gets closer,measurements are made todetermine if the two matingsurfaces are aligned. If they seemto be aligned, the orbiter ismoved slightly closer to the ETand more measurements aretaken. If they are not aligned, theorbiter is repositioned slightlyand then rechecked. This processof checking for alignment, repositioning,and moving closer isrepeated until the orbiter and ETmating surfaces are brought intocontact and the two are secured.Due to the critical nature of thistask, a more precise guidingtechnique was desired. A laserbasedtargeting system wascreated that can be used to alignthe mating components withmore precision and ease thancurrently possible.The laser targeting system iscomposed of a laser mount thatgoes on the ET side and a targetthat goes inside the orbiter. Twosystems are required for eachmate, one for each side of the ETand orbiter. The targets, whichare made of a type of plastic, fitover the screws used to secure theattachment nut inside the orbiter.This nut is used to capture thebolt for connection to the ET. Thetargets are positioned to beperfectly centered with respect tothis bolt.The laser mounts (see figure2) attach to the back side of thebolt clearance holes in the ETfixtures. The mounts are designedto fit snugly within the152

Research and Technology 1998can tell exactly, to within 1/16inch, how far out of alignment theorbiter is at any given time. Twosets are used to help ensure bothsides of the orbiter are at thecorrect height necessary for mating.Figure 2. Laser Mountclearance holes to provide thenecessary concentricity for thelaser. The laser is positionedwithin the mount to shine downthe center of the clearance holeand directly through the center ofthe bolt hole. When the orbiter iswithin range, a window cut intothe mount allows the user to lookdirectly down the bolt hole andinto the aft compartment to seewhere the laser spot falls on thetarget. The target is equippedwith a graded scale so the userThis system has alreadyundergone preliminary testingduring the mating operation ofSTS-88. Targets were not able tobe installed, but the laser mountwas tested for fit and functionality.The laser mount was found to fitextremely well within the ETfixture and the laser spot could beeasily seen on the protectivebacking placed behind the attachmentnut inside the orbiter. Also,using the inner diameter of the nutas a reference, the laser spot wasused to roughly determine theposition of the orbiter. The positiondetermined in this fashioncorresponded well to the positiondetermined using the currentprocedure. A full test of thesystem is planned for the matingoperation of Columbia missionSTS-93.Contact: C.B. Mizell (Carolyn.Mizell-1@ksc.nasa.gov), MM-H-A, (407) 867-7705Participating Organization: DynacsEngineering Co., Inc. (R.B. Cox andJ. Donahue)153

Electronics and InstrumentationMain Three Contamination Monitoring CartThe Contamination MonitoringLaboratory at KSC developeda system that provides threetypes of real-time molecularcontamination monitoring in onesystem for support of highlysensitive payload processing. Itincorporates an airborne hydrocarbonmonitoring system basedon Fourier Transform Infrared(FTIR) technology, real-timeoptical fallout monitors to monitorparticulate fallout, and SurfaceAcoustic Wave (SAW) nonvolatileresidue (NVR) monitorsfor sensing molecular contamination.The system consists of aportable cart suitable for use inclass 1, division 2, environments(see the figure) that is electromagneticinterference (EMI) shielded.The capability to monitorcontaminants is essential in orderto protect sensitive optical payloadsfrom performance degradationcaused by the deposition ofsurface films, other molecularcontamination, and particulatefallout. Commonly used hydrocarbonmonitoring instrumentation,such as flame ionizationdetectors, yields no informationabout the source or identity of thecompounds they detect. TheFTIR technology with its inherentability to discriminate a largenumber of compounds offers atremendous advantage over othertypes of instrumentation. Recentdevelopments in the areas of realtimedetection of particulatefallout and nonvolatile residueshave, for the first time, allowedcreation of an integrated instru-ment to provide fairly completemonitoring of the contaminationrisk to a payload during groundprocessing.The hydrocarbon monitoringsubsystem consists of two modifiedMIDAC FTIR instrumentsmounted in a cart; a computerproviding control, user interface,and communications; and asampling system. The graphicaluser interface runs on the cartcontroller computer, which has akeyboard, mouse, and monitor.The hydrocarbon portion of thecart is capable of measuring avariety of compounds and can bereconfigured to accommodatenew compounds of interest. TheMIDAC instruments were modifiedby the addition of a smallcomputer inside the instrumentcase that controls the operation ofthe FTIR and provides deconvolutionof spectral data. EachFTIR module sends gas concentrationdata to the cart controllercomputer, is equipped with a 1.8-meter gas cell, and runs at aresolution of 4 wavenumbers.The sampling system consists oftwo eductor pumps supplied bythe system purge gas. There arealso flow failure indicators thatare monitored by the cart controllercomputer. The FTIR modulemakes use of a classical leastsquare (CLS) algorithm in theanalysis of spectral data. Thetraditional CLS method has beenmodified by the use of baselinecorrection algorithms, whichcorrect errors due to instrumentwarmup, aging of the source, anddegradation of the optics due tocontamination. This correction isaccomplished by performing aparametric shape fit for thebaseline using three parameters:bend, tilt, and offset.The NVR’s are monitoredwith a Femtometrics SAW devicethat consists of a control unitinside the purged cart and asensor head with an exposedquartz crystal to collect theresidue. The increase in mass dueto the residue deposition causes ashift in the resonant frequency ofthe crystal, which then can beused to quantify the residuemass. The SAW is extremelysensitive, roughly 100 times thesensitivity of a Quartz CrystalMicrobalance. A 50-hertz shift inthe frequency of the SAW crystalcorresponds to only 1 nanogramper square centimeter massdensity.Particulate fallout measurementsare made by optical falloutmonitors (OFM’s) that weredeveloped at KSC. These instrumentsmeasure the light scatteredfrom a specular surface by theparticles which land on thatsurface. This instrument iscalibrated to read out in “percentarea coverage,” which is the totalfractional area of the witnessplate obscured by particles.The data from the two FTIRmodules, the two SAW devices,and the two OFM’s are integratedinto a single software packagethat runs on the cart controllercomputer. Here, the data arelogged in a disk file and presentedto the user in several154

Research and Technology 1998FTIR 1CartStatusPCRorVPFFacilityMonitoringStationKSCAREAFTIR 2Serial LinkEthernetNVR 1NVR 2OFM 1OFM 2CartControllerComputerOtherInterestedPartiesInternet(by permission)LANContaminationMonitoringInstrumentsRemoteMonitoring StationContamination Monitoring Cart Data Flowforms, including tabular andgraphical. The user can opt toview any or all the cart measurements.The cart controller softwarewas written in MicrosoftVisual Basic. All the data fromthe cart is put into a single datastream and sent via a serial link toa remote computer that can belocated in another building.Here, the data is presented in thesame way as on the cart controllercomputer, so the user at theremote site sees exactly the samedata in real time. This remotesystem also is configured as auser datagram protocol (UDP)server and, if connected to a localarea network that supports theInternet Protocol, can broadcastthe cart data in real time to manyremote users simultaneouslyanywhere in the world. Theseremote users can see the samescreens as the local users but canselect their own options for whichdata to view. The server can beconfigured to only allow certaindomains to access the informationso the availability of the data canbe restricted to only those whoare authorized to see it. This isthe same technology that is usedfor “Internet broadcasts” of videoand audio. To view the data fromanywhere in the world, all that isrequired is the UDP client software(also written in Visual Basic)and a personal computer compatiblewith an Internet connectionand authorization on the UDPserver to allow the user to connect.Contacts: J.S. Abernathy (Jean.Abernathy-1@ksc.nasa.gov), NN-M4,(407) 867-6152; and P.A. Mogan,MM-G2, (407) 867-9167Participating Organization: DynacsEngineering Co., Inc. (C.J. Schwindt andC.B. Mattson)155

Electronics and InstrumentationThermographic Inspection of SubsurfaceVoids in Composite StructuresComposite structures arebecoming more prevalent atKSC and in many high technologyindustries. The ability tonondestructively evaluate compositestructures to detect andlocate surface and subsurfacedefects is, therefore, becomingincreasingly important. Infrared(IR) thermography can be extremelyuseful in this type ofnondestructive evaluation (NDE).Large temperature differencesin very hot objects can be seen aschanges in color, as in the color ofa flame or a star. In the sameway, slight temperature variations,at or about room temperature,can be seen as changes in theIR range of the electromagneticspectrum (wavelengths usually inFigure 1. Surface Variationsthe 1- to 20-micron range). Inthermography, detectors sensitiveto IR wavelengths are used toexamine the thermal behavior oftest objects. As an object’s temperaturechanges, the amount ofenergy it emits in the detectorrange also changes. Using anarray of detectors, an IR cameraconverts these differing energyoutputs to video images of differingcolors or gray scales.Many objects change temperatureinherently over time andcan be easily studied by monitoringtheir behavior with an IRcamera. For objects that do notinherently change temperature,heat excitation can be used so thebehavior of the object duringcooling can be examined.Flashlamps were used as theheating source in all experimentsconducted for this report.Flashlamps emit a short burst ofmainly visible and IR radiation,part of which is reflected at theobject’s surface; a large part isabsorbed. The absorbed radiationis turned into heat at the object’ssurface, which increases itstemperature. After the flash, thesurface temperature slowlyreturns to ambient as the extraheat dissipates deeper into thetest object and out into the surroundingenvironment. Theamount of excitation energyinitially absorbed and the rate atwhich the surface returns toambient temperature can both beused to detect anomalies on thesurface of and within the testobject.Immediately after the excitationpulse (the flash), hotter orcooler areas show where more orless energy was initially absorbedby the object. Figure 1 shows anobject with a temperature gradientfrom top to bottom as well asa small “X” and a square (top leftand right center, respectively)which were scratches in thesurface and several “hot spots”(lower left and center). Thesewere all caused by differences ina reflective surface coating on thetest object. Places that appeardarker in the image are actuallyhotter and represent areas thatwere not as completely coveredby the reflective coating.As the object cools, anomalieswithin the test object can bedetected through variations in therate of surface cooling. The156

Research and Technology 1998dissipation of heat from the surface happensthrough three different routes: (1) from the surfaceinto the surrounding environment, (2) from hotterareas on the surface laterally to cooler ones, and (3)from the surface into and through the test object.Given the proper environmental and initial conditions,heat loss through the first two routes will befairly constant across the object’s surface. In thatcase, areas that exhibit anomalous cooling must bedue to variations in heat flow through the testobject.Figure 2. Subsurface DefectsThe rate of heat flow through the test object isdependent upon the path the heat must travel. Thepresence of good heat conductors or good insulatorsalong this path will affect how quickly the heat isable to leave the surface and how quickly thesurface can cool. For example, in these experiments,the presence of voids (air pockets) in the interior ofthe composite structure was of specific interest. Airis a better insulator than the materials that make upthe composite structure so heat flow is slower alonga path with an air pocket. This results in the surfaceabove the air pocket remaining at a higher temperaturethan the surrounding surface for a longer time.Hot spots that were not immediately visible whichappear during cooling could indicate possible voidswithin the structure. Figure 2 shows several indicationsof voids in a preprogrammed test panel. Boththe size and shape of the voids are clearly visible.The rightmost and bottom-center defects are both1/4 inch in diameter and the total field of view isapproximately 6 by 8 inches. The resolution ofthermography is one reason it has proven so effectivein this type of evaluation.Thermography is a fairly old field, yet improvementsare happening at an incredible rate. Theability of thermography to work so well withcomposite materials coupled with the dramaticincrease in IR detector capabilities suggests thatthermography will play a more important role inNDE in the immediate future.Contacts: C.B. Mizell (Carolyn.Mizell-1@ksc.nasa.gov),MM-H-A, (407) 867-7705; and C.K. Davis, PK-H, (407) 861-3636Participating Organization: Dynacs Engineering Co., Inc.(J. Donahue and S.W. Thayer)157

Electronics and InstrumentationAutomatic Calibration Station for the UniversalSignal Conditioning Amplifier (USCA)The goal of this project is todesign an automatic calibrationstation for the USCA. TheUSCA is a self-configuring amplifierdesigned to interface with avariety of transducers. Parameterssuch as gain, excitationvoltage, sampling rate, andfiltering are automatically setbased on information stored in asmall memory device attached tothe transducer. The data on theTransducer Electronic Data Sheet(TEDS) is read by the USCAimmediately after the connectionto the transducer is detected.Calibration factors stored in theUSCA’s memory are used toensure the accuracy of measurementsis maintained withinspecifications.Following the manufacturingprocess, the USCA has to be fullycalibrated before deployment inthe field. The calibration has tobe repeated periodically (every 1or 2 years). The calibrationprocedure also has to be repeatedfollowing any repairs that involvecomponents associated with theanalog circuitry. The calibrationprocess includes measuring thereference voltages that the USCAuses for its self-calibration,measuring the precision resistorsused for current measurementsand current excitation, correctingfor offsets, and others. Themanual process takes about 30minutes to complete when conductedby an experienced technician.The USCA requires certainparameters to be stored in itsnonvolatile memory in order toperform its continuous selfcalibration.These parametersinclude three reference voltages,zero offsets, current sensingresistor values, excitation resistordivider ratios, and input voltageresistor divider ratios. A combinationof custom-developedsoftware in the USCA and aLabView-based program runningon a personal computer is used inconjunction with an externalvoltage/current source to fullyautomate the calibration process.The automated calibration processperforms additional detailedtests that are not normally conductedduring manual calibrationand is expected to take about 15minutes to completely calibrate aUSCA.Key accomplishments:• Started the design of theAutomated Calibration Station.• Developed a method to fullycalibrate a USCA without theneed to remove it from itssealed enclosure.Key milestone:• Evaluate the performance ofthe system and refine thesoftware if needed.Contact: C.M. Ihlefeld (Curtis.Ihlefeld-1@ksc.nasa.gov), MM-G2-A, (407) 867-6747Participating Organization: DynacsEngineering Co., Inc. (P.J. Medelius,J.D. Taylor, J.S. Moerk, J.J. Henderson,and J.A. Rees)158