NASA Academy of Aerospace Quality (AAQ) Mini-Workshop Agenda

Transcription

1 NASA Academy of Aerospace Quality (AAQ) Mini-Workshop Agenda Held in Conjunction with NASA Quality Leadership Forum (QLF) March 22, 2012 Radisson at the Port Resort, Salon II, QLF Sessions Radisson at the Port Resort, Jamaica Room, AAQ Sessions Whisky Romeo Zulu IMAX Movie Wednesday, March 16 starting at 7:00 p.m. at KSC Visitor Center Agenda Item Start Time Duration End Time Brian Hughitt NASA Headquarters 7:45 8:00 15 QLF Welcome and Introduction (Salon II) Enrique Pineyro Filmmaker 8: :00 Whisky Romeo Zulu AAQ Welcome and Introductions (Jamaica) 9: :25 Jose Nunez, NASA KSC Keynote Address 9: :15 Payload Quality Assurance Ken Crane, NASA MSFC Using NASA Quality Standards 10: :35 Karen Hackney, Western Kentucky University Kentucky Sat-1 Portion of NASA's Glory Mission 10: :55 Break 10: :10 William Hollerman, University of Louisiana at Lafayette Inexpensive Student-Based Space Payload Projects Ross Fontenot, Alabama A&M University Developing Payloads for Space-Based Triboluminescent Impact Sensors Iqbal Shareef, Bradley University ISS SARJ Race Ring Damage Simulation and Durability Test for Life Extension 11: :30 11: :50 11: :10

2 Lunch and Networking 12: :30 Brian Hughitt, NASA HQ Fit of AAQ with NASA Quality Assurance Mission Michael Swartout, Saint Louis University Reliability of University-Built Spacecraft: A Statistical Look J.-M. Wersinger, Auburn University The AubieSat Student Satellite Program Flight Experience Lessons Learned and Best Practices Components of a Basic Quality Management System for Academia Group Discussion Jeremy Barnes, AAQ Project Team, Auburn University Using AAQ Modules for Academic Payload Development Alice Smith / Jeff Smith, Auburn University Workshop Reviews and Closing 12: :45 12: :05 1: :25 1: :45 1: :45 2: :00

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4 Jose Nunez, NASA KSC Keynote Address Payload Quality Assurance Jose Nunez, Ph.D., P.E., is currently a Project Manager in the International Space Station (ISS) & Spacecraft Processing Directorate at NASA, Kennedy Space Center. In this capacity, he is responsible for the overall leadership, planning, and organization of the ground processing associated with assigned missions. In his 22 years with NASA, he has performed in multiple leadership and engineering roles across-agency task teams, NASA HQ and field centers. He has worked extensively with Government, Contractor, and University personnel from Brazil, Canada, Japan, Russia, and the European Space Agency. Most significantly, he led the first real time launch-on-need ground integration of the Wrist/Roll joint for the Canadian Robotic Arm (flight UF-1); the European Columbus Module along with its attached Payloads (flight 1E); and two Orbital Replacement Units, the Cargo Transportation Container and Flex Hose Rotary Coupler (HTV-2 flight) launched January 22 nd, 2011, aboard the Japanese Aerospace Exploration Agency s H-II Transfer Vehicle from Tanegashima, Japan. He received his Bachelors in Industrial and Systems Engineering from the University of Florida, and Masters and Doctorate in Industrial Engineering from the University of Central Florida. He teaches Reliability & Maintainability and Decision Analysis in his spare time and is a registered Professional Engineer (P.E.) in the State of Florida. Ken Crane, NASA Safety Center Using NASA Quality Standards Ken Crane is currently serving as the Quality Engineering Technical Discipline Team Lead for the NASA Safety Center in Cleveland Ohio. In this capacity he is responsible for developing technical training material to enhance the QE skills of the NASA workforce and to prepare the next generation of NASA Quality Engineers. Mr. Crane has a wealth of combined NASA Human Space Flight and Quality Engineering experience to apply to this task. His human space flight background includes Space Shuttle, International Space Station, and SkyLab. Additionally, he has 40 years of NASA, DoD, and commercial quality engineering experience; he was selected as Marshall Space Flight Center s (MSFC) inaugural Quality Engineering Expert under the SMA Professional Development Roadmap (PDRM) formal qualification system; he served four years as a Corporate Quality Manager for an eight billion dollar electronic manufacturing services company with fifty plants in seventeen countries and served as the senior expert advisor to the President of the corporation for all quality engineering and assurance matters; he is one of NASA s most senior quality engineers amongst the safety and mission assurance community. He received his Bachelor of Science degree in Electrical Engineering from Mississippi State University. Karen Hackney, Western Kentucky University Kentucky Sat-1 Portion of NASA's Glory Mission This is a report on the Kentucky Sat-1 portion of NASA\'s Glory mission launched from Vandenberg Air Force Base in California Friday March at 5:09:45 a.m. EST which failed

5 to reach orbit. Kentucky Space is a an example of exactly the kind of innovative ideas and ventures that Kentucky is capable of and that will form the basis for the creation of dynamic new companies and high paying jobs across the state, said Gov. Steve Beshear. Kentucky Space is a joint enterprise involving public organizations, colleges, universities and private companies in a student-led initiative for the design, launch and on-orbit operation of small satellites to promote science, technology, engineering, innovation and education. In addition to MSU, its members are: the University of Kentucky, University of Louisville, Western Kentucky University, Murray State University, the Kentucky Space Grant Consortium, Belcan, the Kentucky Council on Postsecondary Education, Kentucky Science and Engineering Foundation, Kentucky Science and Technology Corporation (managing partner), and the Kentucky Community and Technical College System. Student engineering teams have been working on KySat-1, Kentucky Space s first orbiting satellite diligently for over three years. The opportunity to fly it on a NASA flagship mission is extraordinary. This mission represents the first time NASA will have launched CubeSats built by universities to Earth orbit, and KySat-1 will be onboard. Much of the hardware was designed and built at Morehead State University by undergraduate students. It is an historic opportunity and we are proud to be an integral partner. said Dr. Ben Malphrus, chair of MSU s Department of Earth and Space Sciences and director of the Space Science Center. CubeSats are in a class of small research spacecraft called picosatellites and are the brainchild of Bob Twiggs (formerly of Stanford University and now Professor of Space Science at Morehead State) and his colleagues at the California Polytechnic Institute. They have a size of approximately four inches, a volume of about one quart and weigh no more than 2.2 pounds. To place these satellites into orbit by an agency expendable launch vehicle, NASA's Kennedy Space Center in Florida is adapting the Poly-Picosatellite Orbital Deployer, or PPOD. This deployment system, designed and manufactured by the California Polytechnic State University in partnership with Stanford University, has flown previously on Department of Defense and commercial launch vehicles. The Kentucky spacecraft is called KySat-1. It includes a camera to support a scientific outreach program intended for, but not limited to, Kentucky students in kindergarten through 12th grade. The satellite also has a 2.4-gigahertz industrial, scientific and medical band radio, which will be used to test high-bandwidth communications in the license-free portion of the S-band. The communications systems were designed and/or built and integrated at Morehead State. The 21 meter Space Tracking Antenna at Morehead will serve as the primary Earth station to control the satellite and downlink data and telemetry. KySat-1 is the first satellite built in Kentucky and the first to be operated primarily from Morehead State. The satellites will hitch a ride to space with the Taurus rocket's primary payload, NASA's Glory spacecraft. The Glory climate mission, developed by NASA's Science Mission Directorate, will extend the nearly 30-year record of precise measurements of the sun's energy output. It also will obtain first-ever, global measurements of the distribution of tiny airborne aerosol particles. Aerosols represent one of the greatest areas of uncertainty in understanding Earth\'s climate system. The ELaNA project is managed by NASA\'s Launch Services Program at Kennedy. William Hollerman, University of Louisiana at Lafayette Inexpensive Student-Based Space Payload Projects For the last ten years, physics and engineering students at the University of Louisiana at Lafayette (UL Lafayette) have participated in five balloon and two suborbital rocket payload projects funded by the Louisiana Space Grant Consortium (LaSPACE). The main purpose of these programs was to help prepare students to design robust payloads, 2) Test payload components in the space environment, and 3) Obtain useful data to form a baseline for future development. Emphasis will be placed on the trade-offs between payload cost and developing robust space

6 systems. This presentation will discuss results to date and how they can be used to motivate the next generation of space scientists and engineers. Ross Fontenot, Alabama A&M University Developing Payloads for Space-Based Triboluminescent Impact Sensors As the Space Shuttle program ends, NASA is developing the next generation of space vehicles. These new concept designs will require new and innovative structural health monitoring capabilities. One way to solve this problem is with smart impact sensors that use triboluminescent materials. In 2011, the authors reported an 82% increase in the triboluminescence yield of europium dibenzoylmethide triethylammonium (EuD4TEA) by changing the starting material. In addition, it has been shown that introduction of various dopants can enhance the triboluminescent light yield another 400%. In 2012, the authors showed that EuD4TEA and ZnS:Mn triboluminescent light yield varies with impact energy (velocity) and that they are viable candidates for the first ever prototype of an impact sensor. However, if this prototype will be successful, the effects of radiation in a space environment must be known. Iqbal Shareef, Bradley University ISS SARJ Race Ring Damage Simulation and Durability Test for Life Extension The Solar Alpha Rotary Joint (SARJ) is used to rotate the outboard Solar Array Wings and transfer generated power to the International Space Station (ISS). After approximately 83 days of operation, one of the Starboard SARJ mechanisms began to exhibit high drive motor current and increased structural vibrations near the joint. Subsequent inspections showed that the nitrided bearing race on the outboard side of the joint had extensive damage to one of its three rolling surfaces. An extensive investigation of the anomaly showed that it had most probably been caused by high bearing edge stresses that resulted from inadequate lubrication of the rolling contact. To reduce the effect of the damaged surface, astronauts cleaned and lubricated the race ring surface with grease. Race ring grease lubrication led to significant reduction in drive motor current and structural vibration. In this work the influence of operating conditions on the effectiveness of the g rease was investigated experimentally using a vacuum roller-contact test rig. The goal was to determine the number of rotations (time) it takes for the grease to lose its effectiveness as evidenced by significant increase in the ratio of thrust to normal force. A series of experiments have been conducted Roller Testing to Mimic Damage of the ISS SARJ Ring and Durability Test to simulate fifteen years of SARJ operation using the damaged surface. This paper described the results obtained and a very conservative estimate of the time for the contact to undergo lubricant starvation. Brian Hughitt Office of Safety and Mission Assurance NASA HQ Fit of AAQ with NASA Quality Assurance Mission Brian Hughitt serves as the Manager of Quality Assurance for NASA s Office of Safety and Mission Assurance. Brian is responsible for Quality Program policy and requirements; chairs NASA s Quality Leadership Forum and Joint Audit Planning Committee; and manages the Agency s Supplier Assessment System. Prior to joining NASA in January 2004, Brian served over 20 years in various Government and industry Quality Assurance capacities, including: Inspection Department Supervisor for Corning Glass Works; Quality Assurance Group Leader for Newport News Shipbuilding; Quality

7 Assurance & Submarine Safety Branch Head for Naval Sea Systems Command; and Material Control Manager for NAVSEA s Quality Programs Office. During his time at NAVSEA, Brian coauthored the Navy s Material Control Standard and chaired the Navy s Supplier Audit Program. Brian earned a Bachelor s degree in Chemistry from the University of Virginia and is a graduate of George Washington University s Executive Development Program. Michael Swartout, Saint Louis University Reliability of University-Built Spacecraft: A Statistical Look With well over 100 student-built spacecraft launched in the last 20 years, sufficient data exists to study their statistical of reliability. We will show that spacefaring universities can be split into two distinct groups: "flagship" universities with mission capabilities and success rates that are much higher than the "independent" schools. We will look at the trends in mission failure, examine the root causes for the different outcomes of flagships and independents. Finally, we will discuss whether the CubeSat platform (and, especially, NASA\'s support of university CubeSat launches) is a vehicle for improving both the mission utility and mission success of independent schools. (Short answer: probably.) J.-M. Wersinger, Auburn University The AubieSat Student Satellite Program Flight Experience Lessons Learned and Best Practices The AubieSat-1 satellite has been launched as part of the ELaNa III NASA mission on 28 October The satellite is beaconing every minute for 20 seconds. It is charging properly when it is in sunlight. The transmitter works but the satellite does not respond to commands. The beacon signal is weak so it appears that the antennae did not deploy properly. The satellite is also not transmitting when it is in sunlight. This is a result of high temperatures inside the satellite and a command to stop transmission when the temperature is above 60 C. Failure analysis shows that (1) Configuration management was not done properly and as a result precious time was spent reverse engineering by the summer 2011 team; (2) Antenna deployment failure is a result of poor risk analysis; (3) Adequate thermal testing would have revealed that heat is not conducted out of the satellite effectively and that in sunlight the satellite inner temperature raises too high; (4) We should have conducted an Operational Readiness Review before shipping the satellite to the launch provider. Failure to implement these quality control strategies are at the root of the poor performance of the satellite.