Bridging the Research andSpaceflight Operations Gap:The Extra-vehicular Activity  Infrared (EVA IR) Camera         Experie...
NASA Langley Research Center       Extra-vehicular Activity (EVA) Infrared (IR) Camera          Provided New Capability to...
NASA Langley Research Center                               Astronaut Thomas Reiter                                      IS...
NASA Langley Research Center  New Capability: Detect Sub-surface Damage          STS-121 Mission Data from the Sample Box
NASA Langley Research Center              Transitioning Ground Inspection to Orbital                              Inspecti...
NASA Langley Research Center           EVA IR Camera Shuttle Program Support                                              ...
NASA Langley Research Center                                    Project Timeline: Major Milestones                    12/0...
NASA Langley Research Center                          Extensive Systems EngineeringMechanical Systems   Electronic Systems...
NASA Langley Research Center                        Extensive Crew Evaluation
NASA Langley Research Center                   Extensive Verification Testing at LaRCION Radiation             Power Cycle...
NASA Langley Research Center                                Research - Spaceflight Gap•   Culture                         ...
NASA Langley Research Center        Combining Research and Development in the EVA IR Camera                       Project:...
NASA Langley Research Center                                      Bridging the Gap•   What is expected of researchers for ...
NASA Langley Research Center                                                    The Gap in Terms of TRL:                  ...
NASA Langley Research Center               EVA IR Camera Technical Keys to Success•   Retired functional risks early with ...
NASA Langley Research Center             Internal Fabrication Capability Enabled Delivery•   In-house Fabrication Capabili...
NASA Langley Research Center                                         Summary•   Bridging the Gap results in    stronger, m...
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Michael.gazarik

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Michael.gazarik

  1. 1. Bridging the Research andSpaceflight Operations Gap:The Extra-vehicular Activity Infrared (EVA IR) Camera Experience Michael J. Gazarik, Ph.D.Remote Sensing Flight Systems Branch Head NASA Langley Research Center Michael.J.Gazarik@nasa.gov NASA Project Manager Challenge February 2008
  2. 2. NASA Langley Research Center Extra-vehicular Activity (EVA) Infrared (IR) Camera Provided New Capability to Shuttle Program• Langley Research Center led the development of an EVA Infrared Camera that help astronauts remain safe by detecting damage to the orbiter wing leading edge• The EVA Infrared Camera project combined Research and Development (R&D) expertise with Flight Hardware Development expertise
  3. 3. NASA Langley Research Center Astronaut Thomas Reiter ISS EVA-5 August 3, 2006 Impact Damage Flat-bottom Holes
  4. 4. NASA Langley Research Center New Capability: Detect Sub-surface Damage STS-121 Mission Data from the Sample Box
  5. 5. NASA Langley Research Center Transitioning Ground Inspection to Orbital Inspection Ground On-orbitThermography System Thermography System EVA IR LaRC Developed Camera System & Ground Processing • High Power • Low Power • High Weight • Low Weight Ground Inspection: EVA IR Camera Inspection RCC w/ Impact w/ LaRC Developed Processing: Damage RCC w/ Impact Damage
  6. 6. NASA Langley Research Center EVA IR Camera Shuttle Program Support ISS EVA-5 August 2006 STS-114 STS-121 STS-115 F2 Flight Unit 1 Flight Unit 2 Flight Unit 7 (ISS) July 2005 July 2006 Sept 2006
  7. 7. NASA Langley Research Center Project Timeline: Major Milestones 12/03 6/04 8/04 9/04 11/04 12/04 1/05 2/05 3/05 4/05 6/05 7/05 5/05 STS 121 Phase II Decision SMART FlightInitial Proposal: Gate Certification:OBSS System GCAR and STS 114 RAESR Decision Gate STS 114 Phase A Study: OBSS System Phase I/II Phase III Presentation To Poulos: SMART SMART Change to EVA Project Concept: PRCB #1 Project Approval: PRCB #2 System Requirements Review (SRR) FTSOD Crew Flight Equipment Change Control Board System Design Review (SDR) System Acceptance Review (SAR) Delivered Flight HW to JSC for L-10 Bench Review
  8. 8. NASA Langley Research Center Extensive Systems EngineeringMechanical Systems Electronic Systems Firmware Systems Thermal Systems Display Systems
  9. 9. NASA Langley Research Center Extensive Crew Evaluation
  10. 10. NASA Langley Research Center Extensive Verification Testing at LaRCION Radiation Power Cycle Burn-in Thermal Vacuum Random Vibration Shock Bench Handling Drop Electromagnetic Pre-Delivery Acceptance & Compatibility (PDA) Packaged Drop
  11. 11. NASA Langley Research Center Research - Spaceflight Gap• Culture Library? – Researchers “Investigate to Learn” – Developers “Develop What is Required” Buy it and fly it? – Operators “Want Tried and True”• Terminology – Researchers “Test to Experiment and Learn” – Developers “Test to Reduce Risk” Process House?• Perception – Researcher Views Spaceflight Operation as buying systems out-of-house with no technical expertise, a “process” house – Research Centers viewed as a library• Manner that work is done – Researcher’s approach with goal of gaining knowledge • 10% defending, 90% doing – Developer only performs what is required, tasks must come with a rationale • 10% doing, 90% defending• Knowing what needs to be known when – Research claims can’t know when milestones can be met since unsure if experiment or technology will work – Developer’s need for information is based on phase of project • Project phase dictates what details need to known when
  12. 12. NASA Langley Research Center Combining Research and Development in the EVA IR Camera Project: Keys to Success• Project built on thermography expertise of Dr. Bill Winfree and his group – 70+ years experience in applying infrared thermography for structural assessment• Willingness to share knowledge & credit – NDE group shared knowledge with development team (no turf battles) – Recognized development of flight-hardware not in group charter (let others drive)• Development team focused on delivery of capable, flight hardware within given schedule and budget – Gained sufficient measurement expertise (enough to make credible decisions regarding on-orbit measurement) – Provided “drive” to accomplish project goals – Provided flight project discipline: on-time and within budget – Provided technical expertise across all disciplines – Solid risk management: addressed key technical issues early with testing (relied on testing more frequently than review/analysis)• Established collaborative, team environment – OK to make mistakes (focus on how to correct, not why or who) – Shared credit – team success, not individual (egos checked at the door) – Common vision: “Provide Charlie and STS-114 Crew with Critical Capability ”
  13. 13. NASA Langley Research Center Bridging the Gap• What is expected of researchers for the project – Application expertise – Technology expertise – Material expertise – How to test, measure, develop component or system• What is expected of developers for the project – To know enough to meet technical goals of the project at an acceptable risk• What has to happen – Researchers need to understand, or at least appreciate, the limited and focused knowledge that developers require • Let others “drive” – Developers need to understand, or at least appreciate, the application and technology • Need to pass the exam
  14. 14. NASA Langley Research Center The Gap in Terms of TRL: Technology or Application Focused Knowledge Operation Advanced Concepts ckUnderstanding a db F ee Space Validation on rti se Validation In gy lo no ch Tech Development GAP Te 1 2 3 4 5 6 7 8 9 TRL
  15. 15. NASA Langley Research Center EVA IR Camera Technical Keys to Success• Retired functional risks early with environmental testing of off-the-shelf camera system – Thermal, vacuum, and radiation testing validated use of commercial system – Camera system is relatively small, and fairly inexpensive to test• Mitigated operational risks early with frequent crew evaluations – Two Blue room tests and three NBL runs – Provided feedback on how to simplify camera operation – Led to clear requirements for firmware changes (to be made by FLIR in Sweden)• Obtained support from FLIR early in project – Trip to FLIR in early January and frequent telecons and email led to solid understanding of project, required changes – Contract negotiations went smoothly• Environmental testing of engineering unit, though later than projected, provided further confidence in performance of system• Requirements were clear, verifiable, and static• High level of flight-hardware experience on team led to solid, flight-certified design• High-level support of Safety Reviews – Project manager and Development manager wrote majority of RAESR and presented at SMART reviews• Majority of team worked nights, weekends, and holidays from October through July
  16. 16. NASA Langley Research Center Internal Fabrication Capability Enabled Delivery• In-house Fabrication Capability Saved ~3 Months• Fabrication Technician part of Design-Team – Design for build – Increases chance parts fabricated right the first-time – Part is known before it is built• 1400 Fabrication Hours – About 50% for modifications • Coordination of Resources – Ability to set priority of machining operations and meet project schedule
  17. 17. NASA Langley Research Center Summary• Bridging the Gap results in stronger, more capable solutions• Addition of new technology or application results in better systems, better tools for the Agency• Expense is often inefficiency and communication to bridge cultural differences• Agency becomes stronger – developers understand technology – researchers understand development process – everyone passes the 7120.5D exams, and the technology exams
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