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By NASA
The NESC Mechanical Systems TDT provides broad support across NASA’s mission directorates. We are a diverse group representing a variety of sub-disciplines including bearings, gears, metrology, lubrication and tribology, mechanism design, analysis and testing, fastening systems, valve engineering, actuator engineering, pyrotechnics, mechatronics, and motor controls. In addition to providing technical support, the
TDT owns and maintains NASA-STD-5017, “Design and Development Requirements for Space Mechanisms.”
Mentoring the Next Generation
The NESC Mechanical Systems TDT actively participates in the Structures, Loads & Dynamics, Materials, and Mechanical Systems (SLAMS) Early Career Forum that mentors early-career engineers. The TDT sent three members to this year’s forum at WSTF, where early-career engineers networked with peers and NESC mentors, gave presentations on tasks they worked on at their home centers, and attended splinter sessions where they collaborated with mentors.
New NASA Valve Standard to Reduce Risk and Improve Design and Reliability
Valve issues have been encountered across NASA’s programs and continue to compromise mission performance and increase risk, in many cases because the valve hardware was not qualified in the environment as specified in NASA-STD-5017. To help address these issues, the Mechanical Systems TDT is developing a NASA standard for valves. The TDT assembled a team of subject matter experts from across the Agency representing several disciplines including mechanisms, propulsion, environmental control and life support systems, spacesuits, active thermal control systems, and materials and processes. The team has started their effort by reviewing lessons learned and best practices for valve design and hope to have a draft standard ready by the end of 2025.
Bearing Life Testing for Reaction Wheel Assemblies
The Mechanical Systems TDT just concluded a multiyear bearing life test on 40 motors, each containing a pair of all steel bearings of two different conformities or a pair of hybrid bearings containing silicon nitride balls. The testing confirmed that hybrid bearings outperformed their steel counterparts, and bearings with higher conformity (54%) outperformed bearings with lower conformity (52%). The team is disassembling and inspecting the bearings, and initial results have been surprising. The TDT was able to “recover” some of the bearings that failed during the life test and get them running as well as they did when testing began. Some bearings survived over five billion revolutions and appeared like new when they were disassembled and inspected. These results will be published once analysis is complete.
X-57 Design Assessment
The Mechanical Systems TDT was asked by the Aeronautics Mission Directorate to assess the design of the electric cruise motors installed on X-57. The team responded quickly to meet the Project’s schedule, making an onsite visit and attending numerous technical interchange meetings. After careful review of the design, the TDT identified areas for higher-level consideration and risk assessment and attended follow-on reviews to provide additional comments and advice.
CLARREO Pathfinder Inner Radial Bearing Anomaly
The Climate Absolute Radiance and Refractivity Observatory (CLARREO) Pathfinder was designed to take highly accurate measurements of reflected solar radiation to better-understand Earth’s climate. During payload functional testing, engineers detected a noise as the HySICS pointing system was rotated from its normal storage orientation. Mechanical Systems TDT members reviewed the design and inspection reports after disassembly of the inner bearing unit, noticing contact marks on the bore of the inner ring and the shaft that confirmed that the inner ring of the bearing was moving on the shaft with respect to the outer ring. Lubricant applied to this interface resolved the noise problem and allowed the project to maintain schedule without any additional costs.
JPL Wheel Drive Actuator Extended Life Test Independent Review Team
A consequence of changes to its mission on Mars will require the Perseverance Rover to travel farther than originally planned. Designed to drive 20 km, the rover will now need to drive ~91 km to rendezvous and support Mars sample tube transfer to the Sample Retrieval Lander. The wheel drive actuators with integral brakes had only been life tested to 40 km, so a review was scheduled to discuss an extended life test. The OCE Science Mission Directorate Chief Engineer assembled an independent review team (IRT) that included NESC Mechanical Systems TDT members. This IRT issued findings and guidance that questioned details of the JPL assumptions and plan. Several important recommendations were made that improved the life test plan and led to the identification of brake software issues that were reducing brake life. The life test has achieved 40 km of its 137 km goal and is ongoing. In addition, software updates were sent to the rover to improve brake life.
Orion Crew Module Hydrazine Valve
When an Orion crew module hydrazine valve failed to close, the production team asked the Mechanical Systems TDT for help. A TDT member attended two meetings and then visited the valve manufacturer, where it was determined this valve was a scaled-down version of the 12-inch SLS prevalve that was the subject of a previous NESC assessment and shared similar issues. The Orion Program requested NESC materials and mechanical systems support. The Mechanical Systems TDT member then worked closely with a Lockheed Martin (LM) Fellow for Mechanisms to review all the valve vendor’s detailed drawings and assembly procedures and document any issues. A follow-on meeting was held to brief both the LM and NASA Technical Fellows for Propulsion that a redesign and requalification was recommended. These recommendations have now been elevated to the LM Vice President for Mission Success and the LM Chief Engineer for Orion.
NASA’s Perseverance Mars rover selfie taken in July 2024.
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By European Space Agency
In a world first, ESA and Telesat have successfully connected a Low Earth Orbit (LEO) satellite to the ground using 5G Non-Terrestrial Network (NTN) technology in the Ka-band frequency range, marking a crucial step towards making space-based connections as simple as using a mobile phone.
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By NASA
4 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
A crane lowers the steel reflector framework for Deep Space Station 23 into position Dec. 18 on a 65-foot-high (20-meter) platform above the antenna’s pedestal that will steer the reflector. Panels will be affixed to the structure create a curved surface to collect radio frequency signals.NASA/JPL-Caltech After the steel framework of the Deep Space Station 23 reflector dish was lowered into place on Dec. 18, a crew installed the quadripod, a four-legged support structure that will direct radio frequency signals from deep space that bounce off the main reflector into the antenna’s receiver.NASA/JPL-Caltech Deep Space Station 23’s 133-ton reflector dish was recently installed, marking a key step in strengthening NASA’s Deep Space Network.
NASA’s Deep Space Network, an array of giant radio antennas, allows agency missions to track, send commands to, and receive scientific data from spacecraft venturing to the Moon and beyond. NASA is adding a new antenna, bringing the total to 15, to support increased demand for the world’s largest and most sensitive radio frequency telecommunication system.
Installation of the latest antenna took place on Dec. 18, when teams at NASA’s Goldstone Deep Space Communications Complex near Barstow, California, installed the metal reflector framework for Deep Space Station 23, a multifrequency beam-waveguide antenna. When operational in 2026, Deep Space Station 23 will receive transmissions from missions such as Perseverance, Psyche, Europa Clipper, Voyager 1, and a growing fleet of future human and robotic spacecraft in deep space.
“This addition to the Deep Space Network represents a crucial communication upgrade for the agency,” said Kevin Coggins, deputy associate administrator of NASA’s SCaN (Space Communications and Navigation) program. “The communications infrastructure has been in continuous operation since its creation in 1963, and with this upgrade we are ensuring NASA is ready to support the growing number of missions exploring the Moon, Mars, and beyond.”
This time-lapse video shows the entire day of construction activities for the Deep Space Station 23 antenna at the NASA Deep Space Network’s Goldstone Space Communications Complex near Barstow, California, on Dec. 18. NASA/JPL-Caltech Construction of the new antenna has been under way for more than four years, and during the installation, teams used a crawler crane to lower the 133-ton metal skeleton of the 112-foot-wide (34-meter-wide) parabolic reflector before it was bolted to a 65-foot-high (20-meter-high) alidade, a platform above the antenna’s pedestal that will steer the reflector during operations.
“One of the biggest challenges facing us during the lift was to ensure that 40 bolt-holes were perfectly aligned between the structure and alidade,” said Germaine Aziz, systems engineer, Deep Space Network Aperture Enhancement Program of NASA’s Jet Propulsion Laboratory in Southern California. “This required a meticulous emphasis on alignment prior to the lift to guarantee everything went smoothly on the day.”
Following the main lift, engineers carried out a lighter lift to place a quadripod, a four-legged support structure weighing 16 1/2 tons, onto the center of the upward-facing reflector. The quadripod features a curved subreflector that will direct radio frequency signals from deep space that bounce off the main reflector into the antenna’s pedestal, where the antenna’s receivers are housed.
In the early morning of Dec. 18, a crane looms over the 112-foot-wide (34-meter-wide) steel framework for Deep Space Station 23 reflector dish, which will soon be lowered into position on the antenna’s base structure.NASA/JPL-Caltech Engineers will now work to fit panels onto the steel skeleton to create a curved surface to reflect radio frequency signals. Once complete, Deep Space Station 23 will be the fifth of six new beam-waveguide antennas to join the network, following Deep Space Station 53, which was added at the Deep Space Network’s Madrid complex in 2022.
“With the Deep Space Network, we are able to explore the Martian landscape with our rovers, see the James Webb Space Telescope’s stunning cosmic observations, and so much more,” said Laurie Leshin, director of JPL. “The network enables over 40 deep space missions, including the farthest human-made objects in the universe, Voyager 1 and 2. With upgrades like these, the network will continue to support humanity’s exploration of our solar system and beyond, enabling groundbreaking science and discovery far into the future.”
NASA’s Deep Space Network is managed by JPL, with the oversight of NASA’s SCaN Program. More than 100 NASA and non-NASA missions rely on the Deep Space Network and Near Space Network, including supporting astronauts aboard the International Space Station and future Artemis missions, monitoring Earth’s weather and the effects of climate change, supporting lunar exploration, and uncovering the solar system and beyond.
For more information about the Deep Space Network, visit:
https://www.nasa.gov/communicating-with-missions/dsn
News Media Contact
Ian J. O’Neill
Jet Propulsion Laboratory, Pasadena, Calif.
818-354-2649
ian.j.oneill@jpl.nasa.gov
2024-179
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Last Updated Dec 20, 2024 Related Terms
Deep Space Network Jet Propulsion Laboratory Space Communications & Navigation Program Space Operations Mission Directorate Explore More
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By NASA
4 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
NASA/Quincy Eggert NASA’s Armstrong Flight Research Center in Edwards, California, is preparing today for tomorrow’s mission. Supersonic flight, next generation aircraft, advanced air mobility, climate changes, human exploration of space, and the next innovation are just some of the topics our researchers, engineers, and mission support teams focused on in 2024.
NASA Armstrong began 2024 with the public debut of the X-59 quiet supersonic research aircraft. Through the unique design of the X-59, NASA aims to reduce the sonic boom to make it much quieter, potentially opening the future to commercial supersonic flight over land. Throughout the first part of the year, NASA and international researchers studied air quality across Asia as part of a global effort to better understand the air we breathe. Later in the year, for the first time, a NASA-funded researcher conducted an experiment aboard a commercial suborbital rocket, studying how changes in gravity during spaceflight affect plant biology.
Here’s a look at more NASA Armstrong accomplishments throughout 2024:
Our simulation team began work on NASA’s X-66 simulator, which will use an MD-90 cockpit and allow pilots and engineers to run real-life scenarios in a safe environment. NASA Armstrong engineers completed and tested a model of a truss-braced wing design, laying the groundwork for improved commercial aircraft aerodynamics. NASA’s Advanced Air Mobility mission and supporting projects worked with industry partners who are building innovative new aircraft like electric air taxis. We explored how these new designs may help passengers and cargo move between and inside cities efficiently. The team began testing with a custom virtual reality flight simulator to explore the air taxi ride experience. This will help designers create new aircraft with passenger comfort in mind. Researchers also tested a new technology that will help self-flying aircraft avoid hazards. A NASA-developed computer software tool called OVERFLOW helped several air taxi companies predict aircraft noise and aerodynamic performance. This tool allows manufacturers to see how new design elements would perform, saving the aerospace industry time and money. Our engineers designed a camera pod with sensors at NASA Armstrong to help advance computer vision for autonomous aviation and flew this pod at NASA’s Kennedy Space Center in Florida. NASA’s Quesst mission marked a major milestone with the start of tests on the engine that will power the quiet supersonic X-59 experimental aircraft. In February and March, NASA joined international researchers in Asia to investigate pollution sources. The now retired DC-8 and NASA Langley Gulfstream III aircraft collected air measurements over the Philippines, South Korea, Malaysia, Thailand, and Taiwan. Combined with ground and satellite observations, these measurements continue to enrich global discussions about pollution origins and solutions. The Gulfstream IV joined NASA Armstrong’s fleet of airborne science platforms. Our teams modified the aircraft to accommodate a next-generation science instrument that will collect terrain information of the Earth in a more capable, versatile, and maintainable way. The ER-2 and the King Air supported the development of spaceborne instruments by testing them in suborbital settings. On the Plankton, Aerosol, Cloud, ocean Ecosystem Postlaunch Airborne eXperiment mission (PACE-PAX), the ER-2 validated data collected by the PACE satellite about the ocean, atmosphere, and surfaces. Operating over several countries, researchers onboard NASA’s C-20A collected data and images of Earth’s surface to understand global ecosystems, natural hazards, and land surface changes. Following Hurricane Milton, the C-20A flew over affected areas to collect data that could help inform disaster response in the future. We also tested nighttime precision landing technologies that safely deliver spacecraft to hazardous locations with limited visibility. With the goal to improve firefighter safety, NASA, the U.S. Forest Service, and industry tested a cell tower in the sky. The system successfully provided persistent cell coverage, enabling real-time communication between firefighters and command posts. Using a 1960s concept wingless, powered aircraft design, we built and tested an atmospheric probe to better and more economically explore giant planets. NASA Armstrong hosted its first Ideas to Flight workshop, where subject matter experts shared how to accelerate research ideas and technology development through flight. These are just some of NASA Armstrong’s many innovative research efforts that support NASA’s mission to explore the secrets of the universe for the benefit of all.
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Last Updated Dec 20, 2024 EditorDede DiniusContactSarah Mannsarah.mann@nasa.govLocationArmstrong Flight Research Center Related Terms
Armstrong Flight Research Center Advanced Air Mobility Aeronautics C-20A DC-8 Earth Science ER-2 Flight Opportunities Program Quesst (X-59) Sustainable Flight Demonstrator Explore More
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