Timothy J. Collins

Truss Performance and Packaging Metrics

In the present paper a set of performance metrics are derived from first principals to assess the efficiency of competing space truss structural concepts in terms of mass, stiffness, and strength, for designs that are constrained by packaging. The use of these performance metrics provides unique insight into the primary drivers for lowering structural mass and packaging volume as well as enabling quantitative concept performance evaluation and comparison. To demonstrate the use of these performance metrics, data for existing structural concepts are plotted and discussed. Structural performance data is presented for various mechanical deployable concepts, for erectable structures, and for rigidizable structures.

Preliminary Design Considerations for 10-40 Meter-Diameter Precision Truss Reflectors

A simplified preliminary design capability for erectable precision segmented reflectors is presented. This design capability permits a rapid assessment of a wide range of reflector parameters as well as new structural concepts and materials. The preliminary design approach was applied to a range of precision reflectors from 10 meters to 100 meters in diameter while considering standard design drivers. The design drivers considered were: weight, fundamental frequency, launch packaging volume, part count, and on-orbit assembly time. For the range of parameters considered, on-orbit assembly time was identified as the major design driver. A family of modular panels is introduced which can significantly reduce the number of reflector parts and the on-orbit assembly time.

A history of astronaut construction of large space structures at NASA Langley Research Center

During the 1970s through the early 1990s, NASA Langley Research Center (LaRC) conducted studies for the design and construction of large space structures in Low Earth Orbit (LEO). The Langley studies focused on the design and construction of erectable space structures. The construction studies evaluated assembly methods using astronauts with and without mechanized foot-restraints. Astronaut construction was shown to be very effective and efficient when the structure and the construction methods were developed in parallel. This paper presents an overview of the LaRC astronaut construction studies of erectable structures, including a database of assembly rates and lessons learned. In addition this paper presents potential applications of erectable structure assembly methods using EVA astronauts and a suggested integrated approach for construction of large space structures.

A Versatile Lifting Device for Lunar Surface Payload Handling, Inspection & Regolith Transport Operations

Devices for lifting and transporting payloads and material are critical for efficient Earth‐based construction operations. Devices with similar functionality will be needed to support lunar‐outpost construction, servicing, inspection, regolith excavation, grading and payload placement. Past studies have proposed that only a few carefully selected devices are required for a lunar outpost. One particular set of operations involves lifting and manipulating payloads in the 100 kg to 3,000 kg range, which are too large or massive to be handled by unassisted astronauts. This paper will review historical devices used for payload handling in space and on earth to derive a set of desirable features for a device that can be used on planetary surfaces. Next, an innovative concept for a lifting device is introduced, which includes many of the desirable features. The versatility of the device is discussed, including its application to lander unloading, servicing, inspection, regolith excavation and site preparation. A...

Effects of Initial Geometric Imperfections On the Non-Linear Response of the Space Shuttle Superlightweight Liquid-Oxygen Tank

Abstract The results of an analytical study of the elastic buckling and non-linear behavior of the liquid-oxygen tank for the new Space Shuttle superlightweight external fuel tank are presented. Selected results that illustrate three distinctly different types of non-linear response phenomena for thin-walled shells which are subjected to combined mechanical and thermal loads are presented. These response phenomena consist of a bifurcation-type buckling response, a short-wavelength non-linear bending response, and a non-linear collapse or “snap-through” response associated with a limit point. The effects of initial geometric imperfections on the response characteristics are emphasized. The results illustrate that the buckling and non-linear response of a geometrically imperfect shell structure subjected to complex loading conditions may not be adequately characterized by an elastic linear bifurcation buckling analysis, and that the traditional industry practice of applying a buckling-load knock-down factor can result in an ultra-conservative design. Results are also presented that show that a fluid-filled shell can be highly sensitive to initial geometric imperfections, and that the use a buckling-load knock-down factor is needed for this case.

Nonlinear Behavior of Space Shuttle Superlightweight Liquid-Oxygen Tank Under Prelaunch Loads

The new Space Shuttle superlightweight external fuel tank e ew for the e rst time on 2 June 1998 (Space Transportation System-mission 91 ). We present results of elastic linear-bifurcation buckling and nonlinear analyses of one of its major components; that is, the liquid-oxygen tank. The contents include an overview of the structure and a brief description of the e nite element code that was used to conduct the analyses. Results are presented that illustrate three distinctly different types of nonlinearresponsephenomena for thin-walled shells that aresubjected to combined mechanical and thermal loads that launch-vehicle shell designers may encounter. A procedure is demonstrated that can beused by structural analysts and designers to obtain reasonable, conservative estimates of linear-bifurcation, buckling-load knockdown factors for shells that are subjected to complex loading conditions or to characterize the effects of initial geometric imperfections on nonlinear shell response phenomena. Results are also presented that show that the superlightweight liquid-oxygen tank can carry loads in excess of twice the values of the operational prelaunch loads considered and that a e uid-e lled launch-vehicle shell can be highly sensitive to initial geometric imperfections. Presentedherearee vepapersonlarge-scaleanalysesofacomplexshellstructure.Thee rst,longerpaper,“ NonlinearBehaviorofSpaceShuttleSuperlightweight Liquid-OxygenTankUnderPrelaunchLoads,” coversthestructure,theanalysistechnique,someloading cases,andexperimentalverie cationonthemethod.Itis followed by a companion paper, “ Modeling and NonlinearStructural Analysis of a Large-ScaleLaunch Vehicle,” which goes into greaterdepth on themethods, and then by three shorter papers, “ Effects of Welding-Induced Imperfections on Behavior of Space Shuttle Superlightweight Tank,” “ Nonlinear Behavior of Space Shuttle Superlightweight Tank Under Booster Ascent Loads,” and “ Nonlinear Behavior of Space Shuttle Superlightweight Tank Under End-of-Flight Loads,” covering interesting behaviorunder differing load cases. Thesepapersare intended to stand ontheir own (and hencehavesomeredundant introductory material) but are complementary to one another, and so they are presented here together.

Nonlinear Behavior of Space Shuttle Superlightweight Tank Under End-of-Flight Loads

Results of elastic, linear-bifurcation buckling and nonlinear analyses of the new Space Shuttle superlightweight external liquid-oxygen tank are presented for an important end-of-e ight loading condition. These results illustrate an important type of response mode for thin-walled shells subjected to combined mechanical and thermal loads that may be encountered in the design of other liquid-fuel launch vehicles. Linear-bifurcation buckling analyses are presented that predict several nearly equal eigenvalues that correspond to local buckling modes in the aft dome of the liquid-oxygen tank. In contrast, the nonlinear response phenomenon is shown to consist of a shortwavelength bending deformation in the aft elliptical dome of the liquid-oxygen tank that grows in amplitude in a stable manner with increasing load. Imperfection sensitivity analyses are presented that show that the presence of several nearly equal eigenvalues does not lead to a premature general instability mode for the aft dome. For the linear-bifurcation and nonlinear analyses, the results show that accurate predictions of the response of the shell generally require a large-scale, high-e delity, e nite element model, and that a design based on a linear-bifurcation buckling analysis and a buckling-load knockdown factor is overly conservative. Results are also presented that showthatthesuperlightweightliquid-oxygentankcansupportloadsin excessofapproximately1.9 timesthevalues of the operational loads considered.

Support Trusses For Large Precision Segmented Reflectors: Preliminary Design And Analysis

Precision Segmented Reflector (PSR) technology is currently being developed for a range of future applications such as the Large Deployable Reflector (LDR). This paper outlines the structures activities at NASA Langley Research Center in support of the PSR program. Design concepts are explored for erectable and deployable support structures which are envisioned to be the backbone of these precision reflectors. Important functional requirements for the support trusses related to stiffness, mass, and surface accuracy are reviewed. Proposed geometries for these structures and factors motivating the erectable and deployable designs are discussed. Analytical results related to stiffness, dynamic behavior, and surface accuracy are presented and considered in light of the functional requirements. Results are included for both a 4-meter-diameter prototype support truss which is currently being designed as the Test Bed for the PSR technology development program, and for two 20-meter-diameter support structures. For the most likely ground support conditions, the maximum gravity-induced deflection of the Test Bed support truss (with 10 kg/m2 panels) was determined to be approximately 50 μm, and the rms surface error was 12 μm. For the same support conditions, the Test Bed fundamental frequencies were between 30 Hz and 40 Hz. It is shown that if the secondary optical system is supported by a simple tripod design, the first six vibration modes are likely to be dominated by the secondary system. The 20-meter-diameter support trusses were found to be quite stiff for structures of such large size, having maximum deflections on the order of 0.35 mm in a 1-g environment. When considered as part of a reflector system, these support trusses had maximum deflections of 6-11µm under slewing loads, and free-free fundamental frequencies of 6-8 Hz.

Effects of Welding-Induced Imperfections on Behavior of Space Shuttle Superlightweight Tank

Results of linear-bifurcation buckling and nonlinear analyses of the Space Shuttle superlightweight external liquid-oxygen tank are presented for an important prelaunch loading condition. These results show the effects of actual, measured welding-induced initial geometric imperfections on an important response mode for thin-walled shellsthataresubjectedtocombinedmechanicalandthermalloads.Thistypeofinitialgeometricimperfectionmay be encountered in the design of other liquid-fuel launch vehicles. Results are presented that show that the liquidoxygen tank will buckle in the barrel section, but at load levels nearly four times the magnitude of the operational load level, and will exhibit stable postbuckling behavior. The actual measured imperfections are located in this sectionofthetank. Resultsofimperfection sensitivity analysesarepresented thatshowthat thelargestdegradation in the apparent membrane stiffnesses of the liquid-oxygen tank barrel section is caused by an imperfection shape that is in the form of the linear-bifurcation buckling mode with a relatively small amplitude. These results also show that the effect of the relatively large-amplitude measured imperfection is benign.

Nonlinear Behavior of Space Shuttle Superlightweight Tank Under Booster Ascent Loads

Results of linear-bifurcation and nonlinear analyses of the Space Shuttle superlightweight (SLWT) external liquid-oxygen (LO2) tank for an important early booster ascent loading condition are presented. These results for thin-walled linear elastic shells that are subjected to combined mechanical and thermal loads illustrate an important type of response mode that may be encountered in the design of other liquid-fuel launch vehicles. Linear-bifurcation analyses are presented that predict several nearly equal eigenvalues that correspond to local buckling modes in the forward ogive section of the LO 2 tank. In contrast, the nonlinear response phenomenon is shown to consist of short-wavelength bending deformations in the forward-ogive and barrel sections of the LO2 tank that grow in amplitude in a stable manner with increasing load. Imperfection sensitivity analyses are presented that show that the presence of several nearly equal eigenvalues does not lead to a premature general instability mode for the forward-ogive section. For the linear-bifurcation and nonlinear analyses, the results show that accurate predictions of the response of the shell generally require a large-scale, high-e delity, e nite element model, and that a design based on a linear-bifurcation buckling analysis and a buckling-load knockdown factor is overly conservative. Results are presented that show that the SLWT LO 2 tank can support loads in excess of approximately 2.6 timesthevaluesof theoperationalloads considered. In addition, results are presented that show that local bending deformations may cause failure of the thermal protection system (TPS) at load levels less than the load level corresponding to structural collapse. Results are presented that can be used to estimate the load level at which TPS failure is likely to occur.