ALBERT

Description: The John C. Stennis Space Center (SSC) provides test operations services to a variety of customers, including NASA, DoD, and commercial enterprises for the development of current and next-generation rocket propulsion systems. Many of these testing services are provided in the E-Complex test facilities composed of three active test stands (E1, E2, & E3) and 7 total test positions. Each test position is outfitted with unique sets of data acquisition and controls hardware and software that record both facility and test article data and enable safe operation of the test facility. This paper addresses each system in more detail including efforts to upgrade hardware and software.

Description: The harsh rocket propulsion test environment will expose any inadequacies associated with preexisting instrumentation technologies, and the criticality for collecting reliable test data justifies investigating any encountered data anomalies. Novel concepts for improved systems are often conceived during the high scrutiny investigations by individuals with an in-depth knowledge from maintaining critical test operations. The Intelligent Strain Gauge concept was conceived while performing these kinds of activities. However, the novel concepts are often unexplored even if it has the potential for advancing the current state of the art. Maturing these kinds of concepts is often considered to be a tangential development or a research project which are both normally abandoned within the propulsion-oriented environment. It is also difficult to justify these kinds of projects as a facility enhancement because facility developments are only accepted for mature and proven technologies. Fortunately, the CIF program has provided an avenue for bringing the Intelligent Strain Gauge to fruition. Two types of fully functional smart strain gauges capable of performing reliable and sensitive debond detection have been successfully produced. Ordinary gauges are designed to provide test article data and they lack the ability to supply information concerning the gauge itself. A gauge is considered to be a smart gauge when it provides supplementary data relating other relevant attributes for performing diagnostic function or producing enhanced data. The developed strain gauges provide supplementary signals by measuring strain and temperature through embedded Karma and nickel chromium (NiCr) alloy elements. Intelligently interpreting the supplementary data into valuable information can be performed manually, however, integrating this functionality into an automatic system is considered to be an intelligent gauge. This was achieved while maintaining a very low mass. The low mass enables debond detection and temperature compensation to be performed when the gauge is utilized on small test articles. It was also found that the element's mass must be relatively small to avoid overbearing the desired thermal dissipation characteristics. Detecting the degradation of a gauge s bond was reliably achieved by correlating thermal dissipation with the bond s integrity. This was accomplished by precisely coupling a NiCr element with a Karma element for accurately interjecting and quantifying thermal energy. A finite amount of thermal energy is consistently placed in the gauge by electrically powering the NiCr element. The energy will only be temporarily stored before it begins to dissipate into the surrounding structure through the gauge bond. The ability to transmit the energy into the structure becomes greatly inhibited by any discontinuity in the bond s substrate. Therefore, the way the thermal dissipation occurs will reveal even the slightest change in the integrity of the bond.

Description: A monitoring system is disclosed, which includes a base station and at least one sensor unit that is separate from the base station. The at least one sensor unit resides in a dormant state until it is awakened by the triggering of a vibration-sensitive switch. Once awakened, the sensor may take a measurement, and then transmit to the base station the measurement. Once data is transmitted from the sensor to the base station, the sensor may return to its dormant state. There may be various sensors for each base station and the various sensors may optionally measure different quantities, such as current, voltage, single-axis and/or three-axis magnetic fields.

Description: An in situ health monitoring apparatus may include an exciter circuit that applies a pulse to a piezoelectric transducer and a data processing system that determines the piezoelectric transducer's dynamic response to the first pulse. The dynamic response can be used to evaluate the operating range, health, and as-mounted resonance frequency of the transducer, as well as the strength of a coupling between the transducer and a structure and the health of the structure.

Description: This viewgraph presentation reviews the design of the electrical systems that are required for the testing of rockets at the Rocket Propulsion Facility at NASA Stennis Space Center (NASA SSC). NASA/SSC s Mission in Rocket Propulsion Testing Is to Acquire Test Performance Data for Verification, Validation and Qualification of Propulsion Systems Hardware. These must be accurate reliable comprehensive and timely. Data acquisition in a rocket propulsion test environment is challenging: severe temporal transient dynamic environments, large thermal gradients, vacuum to 15 ksi pressure regimes SSC has developed and employs DAS, control systems and control systems and robust instrumentation that effectively satisfies these challenges.

Description: The valve monitoring system is a stand alone unit with network capabilities for integration into a higher level health management system. The system is designed for aiding in failure predictions of high-geared ball valves and linearly actuated valves. It performs data tracking and archiving for identifying degraded performance. The data collection types are cryogenic cycles, total cycles, inlet temperature, body temperature torsional strain, linear bonnet strain, preload position, total travel and total directional changes. Events are recorded and time stamped in accordance with the IRIG B True Time. The monitoring system is designed for use in a Class 1 Division II explosive environment. The basic configuration consists of several instrumentation sensor units and a base station. The sensor units are self contained microprocessor controlled and remotely mountable in three by three by two inches. Each unit is potted in a fire retardant substance without any cavities and limited to low operating power for maintaining safe operation in a hydrogen environment. The units are temperature monitored to safeguard against operation outside temperature limitations. Each contains 902-928 MHz band digital transmitters which meet Federal Communication Commission's requirements and are limited to a 35 foot transmission radius for preserving data security. The base-station controller correlates data from the sensor units and generates data event logs on a compact flash memory module for database uploading. The entries are also broadcast over an Ethernet network. Nitrogen purged National Electrical Manufactures Association (NEMA) Class 4 enclosures are used to house the base-station

Description: A system that includes sensors and data acquisition, wireless data-communication, and data-processing subsystems has been developed as a means of both real-time and historical tracking of information indicative of deterioration in the mechanical integrity and performance of a highgeared ball valve or a linearly actuated valve that operates at a temperature between cryogenic and ambient.