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To sustain the extra-vehicular activity (EVA) rate required to assemble and maintain the International Space Station (ISS), we must enhance our ability to plan, train for, and execute EVAs. An underlying analysis capability must be in place to ensure EVA access to all external worksites either as a starting point for ground training, to generate information needed for on-orbit training, or to react quickly to develop contingency EVA plans, techniques, and procedures. This paper describes a potential flight experiment for application of custom human modeling analysis to plan and train for EVAs to enhance space station functionality and usability through assembly and operation.

The McDonnell Douglas Delta family of launch vehicles, in its more than 30-year history, has proven to be the most reliable spacecraft deployment platform for both the US government and the private sector. This success is due to the continuous and focused application of advanced, affordable engineering and manufacturing technologies in all stages of the design, fabrication, assembly, quality assurance, and launch. One of the recent technological breakthroughs that has enhanced the Delta's service capabilities is the development and use of large composite structures in critical components. Among these structures is the payload fairing, which acts as a protective shroud for the spacecraft. Traditional composite manufacturing techniques, however, are very labor-intensive and time-consuming.

This paper is focusing on considerations pertaining to riveting/fastening systems and assembly methodology currently in use for large aircraft fuselage structures. Discussion of process principles on which current systems are based is addressing distribution of rivets along the aircraft structure, riveting/fastening systems and equipment flexibility. An attempt was made to predict the most probable future equipment development trends based on the need for more efficiency in all aircraft structural assembly and in high level and final assembly areas.

The successes of the long-duration MDA/NASA test programs for advanced life-support systems conducted prior to 1971 were highly dependent on the selection and training of both the test crews that remained inside the test chamber throughout the test periods and the outside operating staff. The operating staff was responsible for overall test performance, crew safety monitoring, operation and maintenance of the test facilities, and collection and maintenance of data. A selection, training, and certification program was developed and performed to ensure operating staff members had the correct technical skills and could work effectively together with the inside crew. A training program was designed to ensure that each selected operating staff member was capable of performing all assigned functions and was sufficiently cross-trained to serve at other positions on a contingency basis, if needed.

A novel robot architecture has been developed which promises cost savings in a variety of applications in Space and on Earth. Utilizing cables in order to effect motion in a general workspace provides large weight savings, as well as high end effector stiffness. The architecture has been built and successfully tested in space. The capability of the robotic system to actuate those switches, dials, and buttons expected in space environments, as well as to read displays and transmit video to earth for operator feedback have been proven, and are discussed herein.

Tactical aircraft have tire lives as low as 3-5 landings per tire causing excessive support costs. The goal of the Improved Tire Life (ITL) program was to begin developing technology to double aircraft tire life, particularly for tactical aircraft. ITL examined not only the tire, but also aircraft/landing gear design, aircraft operations, and the operational environment. ITL had three main thrusts which were successfully accomplished: 1) development of an analytical tire wear model, 2) initiation of technology development to increase tire life, and 3) exploration of new and unique testing methods for tire wear. This paper reports the work performed and the results of the USAF sponsored ITL program.

The paper describes the development, implementation, and benefits of a real-time statistical process control (SPC) data acquisition and response system. The system has been installed on four production CNC riveters and provides enhanced, in-process control of automated fastening machine performance. Each system employs commercially available SPC components. These components, coupled with real-time data acquisition computers, have been integrated with the riveter's controllers and sensors to detect process anomalies as they occur. Real-time knowledge of fastening machine performance is the benefit of this system's approach to SPC. Fastener quality is ensured during the fastening cycle, not after sequences (and perhaps hundreds of rivets) have been completed.

The selection of a life support system for a lunar base depends on many interrelated factors, both programmatic and technical. Many factors are identifiable through the application of a systems engineering approach to the lunar base design, in which base and mission requirements are determined. In addition, there is a range of evolving technology options whose cost and maturity affect their potential for inclusion in base designs. Results of ongoing lunar base design are presented with emphasis on the selection of promising approaches for advanced life support systems that decrease overall cost for a single, permanently inhabited lunar base. We identify critical technology areas that inhibit the selection of closed life support systems and propose alternative basing scenarios to alleviate development and operational costs. In particular, we quantify the cost savings associated with establishing a base at a lunar pole in a region of permanent sunlight.

The Space Constructible Radiator (SCR) Life Test heat pipe performance testing is currently conducted at NASA/Johnson Space Center as part of the Advanced Technology Development Program. The SCR is a dual passage, monogroove heat pipe radiator designed and manufactured by Grumman Aerospace for NASA. The heat pipe has many aerospace applications since it can transport a large amount of heat with a compact lightweight design. As the micro-meteoroid/orbital debris environment worsens, it may be advantageous to add the heat pipe radiator to the Space Station's thermal control system. The SCR Life Test has been operating over the last 10 years and will continue until the year 2000. The overall heat transfer coefficient has decreased from 792 W/K (1500 Btu/Hr-°F) to 475 W/K (900 Btu/Hr-°F) but appears to have stabilized. This paper summarizes the SCR Life Test setup and the test results to date.

The objective of this paper is to present results of MDA's payload vibration isolation system research and development program. A unique isolation system with passive or active capabilities designed to provide isolation down to 10-6 g was developed and tested in our 1-g testbed under simulated microgravity conditions. Fluid and electrical umbilicals are also included in the system. The established isolation system performance requirements were met and the testbed data were used to refine our analytical models for predicting flight performance. Simulations using an updated Space Station configuration showed that the payload microgravity requirement can be met by upgrading the hardware from laboratory to flight tolerances and improving the control system design. The next step is to flight test the systems verified in 1 g on the STS/SPACEHAB using a middeck locker size development unit.

Future military aircraft will demand lower cost and lower weight subsystems that are more reliable, and easier to maintain and support. To identify and develop subsystems integration technologies that could provide benefits such as these to current and future military aircraft, the Air Force Wright Laboratory (WL/FIVE) initiated the Subsystem Integration Technology (SUIT) program in 1991. McDonnell Douglas Aerospace (MDA) together with Pratt and Whitney (PWA), and AlliedSignal Aerospace Systems and Equipment (ASE) was one of three teams that participated in Phase I of the SUIT program. The MDA Team's goal was to conceptually formulate a SUIT approach which would provide significantly reduced weight and costs while increasing cooling and power generation capabilities. These goals were achieved with a new and innovative energy subsystem suite which integrates aircraft and engine subsystem power, cooling, pumping, and controls.

This paper presents an overview of the design and operation of the internal thermal control system (ITCS) developed for Space Station Freedom by the NASA-Johnson Space Center and McDonnell Douglas Aerospace to provide cooling for the resource nodes, airlock, and pressurized logistics modules. The ITCS collects, transports, and rejects waste heat from these modules by a dual-loop, single-phase water cooling system. ITCS performance, cooling, and flow rate requirements are presented. An ITCS fluid schematic is shown and an overview of the current baseline system design and its operation is presented. Assembly sequence of the ITCS is explained as its configuration develops from Man Tended Capability (MTC), for which node 2 alone is cooled, to Permanently Manned Capability (PMC) where the airlock, a pressurized logistics module, and node 1 are cooled, in addition to node 2.

This paper presents the integrated approach toward failure detection, isolation, and recovery/reconfiguration to be used for the Space Station Freedom External Active Thermal Control System (EATCS). The on-board and on-ground diagnostic capabilities of the EATCS are discussed. Time and safety critical failures, as well as noncritical failures, and the detection coverage for each provided by existing capabilities are reviewed. The allocation of responsibility between onboard software and ground-based systems, to be shown during ground testing at the Johnson Space Center, is described. Failure isolation capabilities allocated to the ground include some functionality originally found on orbit but moved to the ground to reduce on-board resource requirements. Complex failures requiring the analysis of multiple external variables, such as environmental conditions, heat loads, or station attitude, are also allocated to ground personnel.