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A consortium of interested parties has conducted an experimental characterization of two Tau parallel kinematic machines which were built as a part of the EU-funded project, SMErobot1. Characteristics such as machine stiffness, work envelope, repeatability and accuracy were considered. This paper will present a brief history of the Tau parallel machine, the results of this testing and some comment on prospective application to the aerospace industry.

Boeing has contracts for military application of twin engine airplanes generically identified in this paper as the MX airplane. Unlike previous derivatives, the MX airplanes are produced with a streamlined manufacturing process to improve cost and schedule performance. The final assembly of each MX airplane includes a series of integration tests, called factory functional tests (FFTs), which are modified from those of typical commercial versions and verify correctness of equipment installation and basic functionalities. Two airplanes have been through the production line resulting in a number of FFT lessons learned. Addressed are the power distribution lessons learned: 1) the expanded coverage of the basic automated power-on generation system test, 2) the need for a manual wire continuity test, 3) salient features of the power distribution tests, and 4) keys to make first pass power distribution test smooth and successful.

Computational Fluid Dynamics airflow models for the Waste and Hygiene Compartment (WHC) in the U.S. Laboratory module and Node 3 were developed and examined. The International Space Station (ISS) currently provides human waste collection and hygiene facilities in the Russian Segment Service Module (SM) which supports a three person crew. An additional set of Russian hardware, known as the system, is planned for the United States Operational Segment (USOS) to support expansion of the crew to six persons. Integration of the Russian system into the USOS incorporates direct Environmental Control and Life Support System (ECLSS) interfaces to allow more autonomous operation. A preliminary design concept was used to create a geometry model to evaluate the air interaction with the module cabin at varied locations and performance of the avionics fan placed in WHC. The Russian and the privacy protection bump-outs (Kabin) were included into the present modeling.

The management of off-nominal situations on-board the International Space Station (ISS) is crucial to its continuous operation. Off-nominal situations can arise from virtually any aspect of ISS operations. One situation of particular concern is the inadvertent release of a chemical into the ISS atmosphere. In sufficient quantities, a chemical release can render the ISS uninhabitable regardless of the chemical's toxicity as a result of its effect on the hardware used to maintain the environment. This is certainly true with system chemicals which are integral components to the function and purpose of the system. Safeguards, such as design for minimum risk, multiple containment, hazard assessments, rigorous safety reviews, and others, are in place to minimize the probability of a chemical release to the ISS environment thereby allowing the benefits of system chemicals to outweigh the risks associated with them. The thermal control system is an example of such a system.

The Carbon Dioxide Removal Assembly (CDRA) is a part of the International Space Station (ISS) Environmental Control and Life Support (ECLS) system. The CDRA provides carbon dioxide (CO2) removal from the ISS on-orbit modules. Currently, the CDRA is the secondary removal system on the ISS, with the primary system being the Russian Vozdukh. Within the CDRA are two Desiccant/Adsorbent Beds (DAB), which perform the carbon dioxide removal function. The DAB adsorbent containment approach required improvements with respect to adsorbent containment. These improvements were implemented through a redesign program and have been implemented on units on the ground and returning from orbit. This paper presents a DAB design modification implementation description, a hardware performance comparison between the unmodified and modified DAB configurations, and a description of the modified DAB hardware implementation into the on-orbit CDRA.

The Shuttle retirement in 2010 will force the ISS program to reconsider how to supply the Station with nitrogen and oxygen for six to ten more years beyond 2010. The major options for post-Shuttle retirement resupply are resupply via transfer vehicle, the use of small Intervehicular Activity (IVA) high pressure tanks, “stockpile” enough gas to support International Space Station (ISS) through end of life, or generate the necessary gases onboard the Station. The method chosen to sustain the ISS will serve as a building block for producing new minimally dependent environmental control and life support systems for future manned missions to the Moon, Mars and beyond.

There is an increasing demand in the aerospace industry for automated machinery that is portable, flexible and light. This paper will focus on a joint project between BROETJE-Automation and Boeing called the Universal Splice Machine (USM). The USM is a portable, flexible and lightweight automated drilling and fastening machine for longitudinal splices. The USM is the first machine of its kind that has the ability not only to drill holes without the need to deburr, (burrless drilling) but also to insert fasteners. The Multi Function End Effector (MFEE) runs on a rail system that is mounted directly on the fuselage using a vacuum cup system. Clamp up is achieved through the use of an advanced electromagnet. A control cart follows along next to the fuselage and includes an Automated Fastener Feeding System. This paper will show how this new advancement has the capabilities to fill gaps in aircraft production that automation has never reached before.

Increased emphasis on standardizing processes and controlling variability in production operations includes validating perishable tools used in daily operations. Even though dealing with reputable manufacturers, many factors including communication, custom specifications and personnel turnover can lead to the perpetuation of mistakes if errors are not discovered and corrective action implemented. However, inspection is costly and inspection costs far outweigh many item costs unless considering product defects. A beneficial balance may be obtained by employing statistical sampling techniques similar to ISO 2859 [1] to verify the quality of incoming tools.

This study was designed to answer what percent of “required” traffic pilots acquire visually using the current “visual acquisition system” of windows, eyes and the Traffic Collision Avoidance System (TCAS). “Required Traffic” was defined as Air Traffic Control (ATC) calls to the research aircraft, TCAS Traffic Alerts and/or TCAS Resolution Advisories. The results of the approximately 40 hours of flight were that the majority of (“required”) traffic was NOT visually acquired (39% visually acquired; 61% not visually acquired). When traffic was identified to the pilots by more than one source, the visual acquisition rate was 58%. For validation purposes, an additional 10 hours of flight observations were made during revenue flights with a major airline. Flight test and airline observations were found to be comparable.

A multi-element fixed control volume integrated air interchange system performance computer model has been developed and upgraded for the evaluation/assessment of atmospheric characteristics inside the crew compartments of the mated Orbiter and International Space Station (ISS). In order to ensure a safe, comfortable, and habitable environment for all the astronauts during the Orbiter/ISS docked period, this model was utilized to conduct the analysis for supporting the early ISS assembly missions. Two ISS assembly missions #2A and #4A were selected and analyzed.

The temperature and humidity of the air within the habitable areas of the International Space Station are controlled by a set of hardware and software collectively referred to as the Temperature and Humidity Control (THC) subassembly. This subassembly 1) controls the temperature of the cabin air based on a crew selected temperature, 2) maintains humidity within defined limits, and 3) generates a ventilation air flow which circulates through the cabin. This paper provides descriptions of the components of the THC subassembly, their performance ranges, and the control approach of the hardware. In addition, the solutions of the design challenges of maintaining a maximum case radiated noise level of NC 45, controlling the cabin air temperature to within ±2°F of a setpoint temperature, and providing a means of controlling microbial growth on the heat exchanger surfaces are described.

As pieces of the International Space Station (ISS) enter their test phase, access to information and data from the test laboratories must be made immediately available to analysts, managers, and customers. The Virtual Laboratory (VLAB) concept provides remote access to laboratory test data and other information, indirectly as archived data or directly as real-time data off the test bed. We applied VLAB to a life support system hardware test (the Trace Contaminant Control System, TCCS) in the Life Support Technology Center (LSTC). In this paper we describe the VLAB concept in the context of the TCCS hardware test.

Friction Stir Welding (FSW) can achieve high quality welds in aluminum alloys that are of interest to the aerospace industry (e.g. alloys 2014, 2219, 7050 and numerous aluminum-lithium alloys). The low distortion solid-phase welds exhibit metallurgical and mechanical properties, including fatigue, which are superior to conventional fusion welds achieved by arc processes. FSW, although a relatively new welding technique, has been systematically developed and proved by The Welding Institute (TWI) under contract to an international group of sponsors, one of which is The Boeing Company. To further validate the process, The Boeing Company conducted separate development activities including detailed mechanical testing of welds made from the FSW process.

The proliferation and growth of microorganisms in the Internal Active Thermal Control System (IATCS) aboard the International Space Station (ISS) has been of significant concern since 2001. Initial testing and assessments of biocides to determine bacterial disinfection capability, material compatibility, stability (rate of oxidative degradation and identification of degradation products), solubility, application methodology, impact on coolant toxicity hazard level, and impact on environmental control and life support systems identified a prioritized list of acceptable biocidal agents including glutaraldehyde, ortho-phthalaldehyde (OPA), and methyl isothiazolone. Glutaraldehyde at greater than 25 ppm was eliminated due to NASA concerns with safety and toxicity and methyl isothiazolone was eliminated from further consideration due to ineffectiveness against biofilms and toxicity at higher concentrations.

International Space Station (ISS) Payload Engineering Integration (PEI) organization adopted the advanced computation and simulation technology to develop integrated electrical system models based on the test data of various sub-units. This system model was used end-to-end to mitigate system risk for the integrated Space Shuttle Pre-launch and Landing configurations. The Space Shuttle carries the Multi-Purpose Logistics Module (MPLM), a pressurize transportation carrier, and the Laboratory Freezer for ISS, a freezer rack for storage and transport of science experiments from/to the ISS, is carried inside the MPLM. An end-to-end electrical system model for Space Shuttle Pre-Launch and Landing configurations, including the MPLM and Freezer, provided vital information for integrated electrical testing and to assess Mission success. The Pre-Launch and Landing configurations have different power supplies and cables to provide the power for the MPLM and the Freezer.

The International Space Station (ISS) program is nearing an assembly complete configuration with the addition of the final resource node module in early 2010. The Node 3 module will provide critical functionality in support of permanent long duration crews aboard ISS. The new module will permanently house the regenerative Environment Control and Life Support Systems (ECLSS) and will also provide important habitability functions such as waste management and exercise facilities. The ISS program has selected the Port side of the Node 1 “Unity” module as the permanent location for Node 3 which will necessitate architecture changes to provide the required interfaces. The USOS ECLSS fluid and ventilation systems, Internal Thermal Control Systems, and Avionics Systems require significant modifications in order to support Node 3 interfaces at the Node 1 Port location since it was not initially designed for that configuration.

A family of water-based sol-gel coatings has been developed as an environmentally-friendly alternative to traditional aerospace finishing materials and processes. The sol-gel hybrid network is based on a reactive mixture of an organo-functionalized silane with a stabilized zirconium complex. Thin films of the material self-assemble on metal surfaces, resulting in a gradient coating that provides durable adhesion for paints, adhesives, and sealants. Use of the novel coating as a surface pretreatment for the exterior of commercial aircraft has enabled environmental, health, and safety benefits due to elimination of hexavalent chromium, and flight test and early fleet survey data support the laboratory observations that the sol gel coating reduces the occurrence of “rivet rash” adhesion failures. Modifications of the basic inorganic/organic hybrid network have yielded multifunctional coatings with promise for applications such as corrosion control and oxidation protection.

This paper will describe the Efficient Assembly Integration and Test (EAIT) system level project operated as a partnership among Boeing business units, universities, and suppliers. The focus is on the successful implementation and sharing of technology solutions to develop a model based, multi-product pulsed line factory of the future. The EAIT philosophy presented in this paper focuses on a collaborative environment that is tightly woven with the Lean Initiatives at Boeing's satellite development center. The prototype is comprised of a platform that includes a wireless instrumentation system, rapid bonding materials and virtual test of guidance hardware there are examples of collaborative development in collaboration with suppliers. Wireless tools and information systems are also being developed across the Boeing Company. Virtual reality development will include university partners in the US and India.

The repairing of commercial aircraft is a complex task. Service engineers at Boeing's Commercial Aviation Services group specialize in providing crucial repair information and technical support for its many customers. This paper details factors that influence Boeing's response time to service requests and how to improve it. Information pertaining to over 5000 service requests from 2008 and 2009 was collected. From analysis of this data set, important findings were discovered. One major finding is that between 6 and 8 percent of service requests are late because time/date stamps used in reports were created in a different time zone.

The Portable Fastener Delivery System or PFDS, has been developed at the Boeing St. Louis facility to streamline the manual fastener installation process. The PFDS delivers various fasteners, on demand, through a delivery tube to an installation tool used by the operator to install the fasteners in an aircraft assembly. This paper describes the PFDS in its current configuration, along with the associated Huck® International (now Alcoa Fastening Systems) installation tooling, as it is being implemented on the F/A-18E/F Nosebarrel Skinning application. As a “portable” system, the PFDS cart can be rolled to any location on the shop floor it might be needed. The system uses a removable storage cassette to cache many sizes and types of fasteners in the moderate quantities that might be required for a particular assembly task. The operator begins the installation sequence by calling for the particular fastener grip length needed using a wireless control pendant.