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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 NASA
Humans are returning to the Moon—this time, to stay. Because our presence will be more permanent, NASA has selected a location that maximizes line-of-sight communication with Earth, solar visibility, and access to water ice: the Lunar South Pole (LSP). While the Sun is in the lunar sky more consistently at the poles, it never rises more than a few degrees above the horizon; in the target landing regions, the highest possible elevation is 7°. This presents a harsh lighting environment never experienced during the Apollo missions, or in fact, in any human spaceflight experience. The ambient lighting will severely affect the crews’ ability to see hazards and to perform simple work. This is because the human vision system, which despite having a high-dynamic range, cannot see well into bright light and cannot adapt quickly from bright to dark or vice versa. Functional vision is required to perform a variety of tasks, from simple tasks (e.g., walking, operating simple tools) through managing complex machines (e.g., lander elevator, rovers). Thus, the environment presents an engineering challenge to the Agency: one that must be widely understood before it can be effectively addressed.
In past NASA missions and programs, design of lighting and functional vision support systems for extravehicular activity (EVA) or rover operations have been managed at the lowest program level. This worked well for Apollo and low Earth orbit because the Sun angle was managed by mission planning and astronaut self-positioning; helmet design alone addressed all vision challenges. The Artemis campaign presents new challenges to functional vision, because astronauts will be unable to avoid having the sun in their eyes much of the time they are on the lunar surface. This, combined with the need for artificial lighting in the extensive shadowing at the LSP, means that new functional vision support systems must be developed across projects and programs. The design of helmets, windows, and lighting systems must work in a complementary fashion, within and across programs, to achieve a system of lighting and vision support that enables crews to see into darkness while their eyes are light-adapted, in bright light while still dark-adapted, and protects their eyes from injury.
Many of the findings of the assessment were focused on the lack of specific requirements to prevent functional vision impairment by the Sun’s brilliance (which is different from preventing eye injury), while enabling astronauts to see well enough to perform specific tasks. Specifically, tasks expected of astronauts at the LSP were not incorporated into system design requirements to enable system development that ensures functional vision in the expected lighting environment. Consequently, the spacesuit, for example, has flexibility requirements for allowing the astronauts to walk but not for ensuring they can see well enough to walk from brilliant Sun into a dark shadow and back without the risk of tripping or falling. Importantly, gaps were identified in allocation of requirements across programs to ensure that the role of the various programs is for each to understand functional vision. NESC recommendations were offered that made enabling functional vision in the harsh lighting environment a specific and new requirement for the system designers. The recommendations also included that lighting, window, and visor designs be integrated.
The assessment team recommended that a wide variety of simulation techniques, physical and virtual, need to be developed, each with different and well-stated capabilities with respect to functional vision. Some would address the blinding effects of sunlight at the LSP (not easily achieved through virtual approaches) to evaluate performance of helmet shields and artificial lighting in the context of the environment and adaptation times. Other simulations would add terrain features to identify the threats in simple (e.g., walking, collection of samples) and complex (e.g., maintenance and operation of equipment) tasks. Since different facilities have different strengths, they also have different weaknesses. These strengths and limitations must be characterized to enable verification of technical solutions and crew training.
NESC TB 2024- discipline-focus-hfView the full article
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By NASA
3 min read
Preparations for Next Moonwalk Simulations Underway (and Underwater)
Latha Balijepalle, a senior database administrator at NASA Ames, encourages others to take a risk and pursue challenges in their work, like trying something new that might open doors to a new opportunity.NASA/Brandon Torres Navarrete When Madhavi Latha Balijepalle noticed that her morning commute took her past NASA Ames Research Center in California’s Silicon Valley, she set a new career goal for herself: working for NASA.
“I started manifesting it, thinking about it every day as I drove by. When I started looking for a new job, I saw an opening and decided to apply,” said Balijepalle, a senior database administrator working at the Airspace Operations Laboratory (AOL) at NASA Ames.
Eight and a half years later, she supports the researchers and developers who research next-generation solutions to advance aircraft technology and air traffic management.
A journey into the unknown
Balijepalle’s journey to NASA started thousands of miles away. She grew up in a small town in southern India, studying electrical engineering in college and establishing a career in information technology, working in C++ and Python.
When her husband found a job opportunity in the United States, Balijepalle’s life took an unexpected turn.
“I never planned to move to America,” said Balijepalle. “It was not easy to come here, even though my husband had a job. I stayed in India for almost nine months, before he found a different job that would help us with my visa and documentation.”
After settling into her new country, growing her family, and developing in her new career, Balijepalle began to ponder her dream job at NASA. She and her younger daughter, a fellow space fan, enjoyed talking about the agency’s work in space, and when a Linux administrator position opened up, she jumped at the chance.
A dream job becomes reality
At the lab, Balijepalle was initially responsible for managing the lab’s Linux servers and applications. Today, she also supports researchers and developers with development, automation, and deployment of their work.
“Latha is the lifeblood of the lab,” said Jeff Homola, co-leader of the Airborne Operations Laboratory at NASA Ames. “Without her unwavering dedication to making sure our systems are safe, secure, up to date, and running smoothly, we would not be able to do what we do in the lab.”
One of Balijepalle’s proudest achievements during her NASA career is her language skills. Growing up, she spoke Telugu and Hindi, and learned English, but communication was still a challenge when she arrived at NASA.
“I spoke English when I came to America, but not as well, and not using the technical language we use at NASA,” said Balijepalle. “I’m proud that I’ve improved my communications skills.”
“Step outside your comfort zone”
Looking back on the commute that changed her life, Balijepalle says she owes it all to being up to the challenge.
“I wasn’t a risk taker, I didn’t think about stepping outside my comfort zone, but as I drove by NASA Ames each day, I started to think about astronauts. They step outside their comfort zone and leave the planet, so maybe I could take a risk, too.”
For those who also dream of working at NASA one day, Balijepalle has some advice: try doing it her way.
“Start thinking about it and manifesting your dream. Maybe it will come true, and maybe it won’t, but you might as well try.”
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