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Mechanical Systems TDT Support Reaches Across NASA Programs


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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.

Attendees gathered at the 13th annual NASA SLAMS Early Career Forum, July 2024

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.

An illustration of how CLARREO Pathfinder will take measurements of Earth (red) and use the Sun (orange) and Moon (green) for regular instrument calibration on ISS

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.

screenshot-2024-12-26-at-10-12-57 am.png

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.
NASA’s Perseverance Mars rover selfie taken in July 2024.

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      A deployer attached to the International Space Station’s Kibo laboratory module launches LignoSat into space. JAXA (Japan Aerospace Exploration Agency) developed the satellite to test using wood as a more sustainable alternative to conventional satellite materials. Researchers previously exposed different woods to space and chose magnolia as the best option for the study, including sensors to evaluate the wood’s strain and its response to temperature and radiation. Researchers also are monitoring whether Earth’s geomagnetic field interferes with the satellite’s data transmission.
      NASA Making microbes in space
      NASA astronaut Suni Williams poses with bacteria and yeast samples for Rhodium Biomanufacturing 03, part of an ongoing examination of microgravity’s effects on biomanufacturing engineered bacteria and yeast aboard the International Space Station. Microgravity causes changes in microbial cell growth, cell structure, and metabolic activity that can affect biomanufacturing processes. This investigation could clarify the extent of these effects and advance the use of microbes to make food, pharmaceuticals, and other products in space, reducing the cost of launching equipment and consumables from Earth.
      NASA A NICER spacewalk
      The International Space Station’s Neutron star Interior Composition Explorer, or NICER, studies neutron stars, the glowing cinders left behind when massive stars explode as supernovas. NASA astronaut Nick Hague installs patches during a spacewalk to repair damage to thermal shields that block out sunlight while allowing X-rays to pass through the instrument. NICER continues to generate trailblazing astrophysics discoveries reported in hundreds of scientific papers.
      NASA Earth from every angle
      From inside the International Space Station’s cupola, NASA astronaut Butch Wilmore photographs landmarks on Earth approximately 260 miles (418 kilometers) below. Crew members have taken millions of images of Earth from the space station for Crew Earth Observations, creating one of the longest-running records of how our planet changes over time. These images support a variety of research, including studies of phenomena such as flooding and fires, atmospheric processes affected by volcanic eruptions, urban growth, and land use.
      NASA An out-of-this-world sunrise
      This photograph captures an orbital sunrise above the lights of Rio de Janeiro and Sao Paulo as the International Space Station orbits above Brazil. This image is one of the millions of photographs taken by crew members for Crew Earth Observations. These images teach us more about our home planet, and studies show that taking them improves the mental well-being of crew members. Many spend much of their free time pursuing shots that, like this one, are only possible from space.
      NASA Vital vitamins
      The BioNutrients investigation demonstrates technology to produce nutrients during long-duration space missions using engineered microbes like yeast. Food stored for long periods can lose vitamins and other nutrients, and this technology could provide a way to make supplements on demand. NASA astronaut Suni Williams prepares specially designed growth packets for the investigation aboard the International Space Station.
      NASA Blowing in the solar wind
      The International Space Station’s robotic hand, Dextre, attached to the Canadarm2 robotic arm, moves hardware into position for the COronal Diagnostic EXperiment, or CODEX. This investigation examines solar wind and how it forms using a solar coronagraph, which blocks out bright light from the Sun to reveal details in its outer atmosphere or corona. Results could help scientists understand the heating and acceleration of the solar wind and provide insight into the source of the energy that generates it.
      NASA Can you hear me now?
      Roscosmos cosmonaut Aleksandr Gorbunov conducts a hearing test in the relative quiet of the International Space Station’s Quest airlock. Crew members often serve as test subjects for research on how spaceflight affects hearing and vision, the immune and cardiovascular systems, and other bodily functions. This research supports the development of ways to prevent or mitigate these effects.
      NASA Exposing materials to space
      Euro Material Ageing, an ESA (European Space Agency) investigation, studies how certain materials age when exposed to the harsh space environment. Findings could advance design for spacecraft and satellites, including improved thermal control, as well as the development of sensors for research and industrial applications. NASA astronaut Suni Williams installs the experiment into the Nanoracks Bishop airlock for transport to the outside of the International Space Station.
      NASA Sending satellites into space
      NASA astronauts Don Pettit and Butch Wilmore remove a small satellite deployer from an airlock on the International Space Station. The deployer had released several CubeSats into Earth orbit including CySat-1, a remote sensor that measures soil moisture, and DORA, a receiver that could provide affordable and accurate communications among small spacecraft.
      NASA Robotic relocation
      The Responsive Engaging Arms for Captive Care and Handling demonstration (Astrobee REACCH) uses the International Space Station’s Astrobee robots to test technology for capturing objects of any geometry or material orbiting in space. This ability could enable satellite servicing and movement to maximize the lifespan of these tools and removal of space debris that could damage satellites providing services to the people of Earth. NASA astronaut Suni Williams checks out an Astrobee fitted with tentacle-like arms and adhesive pads for the investigation.
      NASA Arms to hold
      As part of a program called High school students United with NASA to Create Hardware, or HUNCH, NASA astronaut Nick Hague demonstrates the HUNCH Utility Bracket, a student-designed tool to hold and position cameras, tablets, and other equipment that astronauts use daily. Currently, crew members on the International Space Station use devices called Bogen Arms, which have experienced wear and tear and need to be replaced.
      NASA A Dragon in flight
      The SpaceX Dragon spacecraft fires its thrusters after undocking from the International Space Station as it flies 260 miles (418 kilometers) above the Pacific Ocean west of Hawaii. NASA’s commercial resupply services deliver critical scientific studies, hardware, and supplies to the station.
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