Performing a Large-Scale Modal Test on the B2 Stand Crane at NASA's Stennis Space Center

A modal test of NASAs Space Launch System (SLS) Core Stage is scheduled to occur prior to propulsion system verification testing at the Stennis Space Center B2 test stand. A derrick crane with a 180-ft long boom, located at the top of the stand, will be used to suspend the Core Stage in order to achieve defined boundary conditions. During this suspended modal test, it is expected that dynamic coupling will occur between the crane and the Core Stage. Therefore, a separate modal test was performed on the B2 crane itself, in order to evaluate the varying dynamic characteristics and correlate math models of the crane. Performing a modal test on such a massive structure was challenging and required creative test setup and procedures, including implementing both AC and DC accelerometers, and performing both classical hammer and operational modal analysis. This paper describes the logistics required to perform this large-scale test, as well as details of the test setup, the modal test methods used, and an overview of the results

Modal Test of the NASA Mobile Launcher at Kennedy Space Center

The NASA Mobile Launcher (ML), located at Kennedy Space Center (KSC), has recently been modified to support the launch of the new NASA Space Launch System (SLS). The ML is a massive structureconsisting of a 345-foot tall tower attached to a two-story base, weighing approximately 10.5 million poundsthat will secure the SLS vehicle as it rolls to the launch pad on a Crawler Transporter, as well as provide a launch platform at the pad. The ML will also provide the boundary condition for an upcoming SLS Integrated Modal Test (IMT). To help correlate the ML math models prior to this modal test, and allow focus to remain on updating SLS vehicle models during the IMT, a ML-only experimental modal test was performed in June 2019. Excitation of the tower and platform was provided by five uniquely-designed test fixtures, each enclosing a hydraulic shaker, capable of exerting thousands of pounds of force into the structure. For modes not that were not sufficiently excited by the test fixture shakers, a specially-designed mobile drop tower provided impact excitation at additional locations of interest. The response of the ML was measured with a total of 361 accelerometers. Following the random vibration, sine sweep vibration, and modal impact testing, frequency response functions were calculated and modes were extracted for three different configurations of the ML in 0 Hz to 12 Hz frequency range. This paper will provide a case study in performing modal tests on large structures by discussing the Mobile Launcher, the test strategy, an overview of the test results, and recommendations for meeting a tight test schedule for a large-scale modal test

Validation of Slosh Model Parameters and Anti-Slosh Baffle Designs of Propellant Tanks by Using Lateral Slosh Testing

The slosh dynamics of propellant tanks can be represented by an equivalent mass-pendulum-dashpot mechanical model. The parameters of this equivalent model, identified as slosh mechanical model parameters, are slosh frequency, slosh mass, and pendulum hinge point location. They can be obtained by both analysis and testing for discrete fill levels. Anti-slosh baffles are usually needed in propellant tanks to control the movement of the fluid inside the tank. Lateral slosh testing, involving both random excitation testing and free-decay testing, are performed to validate the slosh mechanical model parameters and the damping added to the fluid by the anti-slosh baffles. Traditional modal analysis procedures were used to extract the parameters from the experimental data. Test setup of sub-scale tanks will be described. A comparison between experimental results and analysis will be presented

Performing a Large-Scale Modal Test on the B2 Stand Crane at NASA's Stennis Space Center

A modal test of NASA's Space Launch System (SLS) Core Stage is scheduled to occur at the Stennis Space Center B2 test stand. A derrick crane with a 150-ft long boom, located at the top of the stand, will be used to suspend the Core Stage in order to achieve defined boundary conditions. During this suspended modal test, it is expected that dynamic coupling will occur between the crane and the Core Stage. Therefore, a separate modal test was performed on the B2 crane itself, in order to evaluate the varying dynamic characteristics and correlate math models of the crane. Performing a modal test on such a massive structure was challenging and required creative test setup and procedures, including implementing both AC and DC accelerometers, and performing both classical hammer and operational modal analysis. This paper describes the logistics required to perform this large-scale test, as well as details of the test setup, the modal test methods used, and an overview and application of the results

Acoustic-Structure Interaction in Rocket Engines: Validation Testing

While analyzing a rocket engine component, it is often necessary to account for any effects that adjacent fluids (e.g., liquid fuels or oxidizers) might have on the structural dynamics of the component. To better characterize the fully coupled fluid-structure system responses, an analytical approach that models the system as a coupled expansion of rigid wall acoustic modes and in vacuo structural modes has been proposed. The present work seeks to experimentally validate this approach. To experimentally observe well-coupled system modes, the test article and fluid cavities are designed such that the uncoupled structural frequencies are comparable to the uncoupled acoustic frequencies. The test measures the natural frequencies, mode shapes, and forced response of cylindrical test articles in contact with fluid-filled cylindrical and/or annular cavities. The test article is excited with a stinger and the fluid-loaded response is acquired using a laser-doppler vibrometer. The experimentally determined fluid-loaded natural frequencies are compared directly to the results of the analytical model. Due to the geometric configuration of the test article, the analytical model is found to be valid for natural modes with circumferential wave numbers greater than four. In the case of these modes, the natural frequencies predicted by the analytical model demonstrate excellent agreement with the experimentally determined natural frequencies

Validation of Slosh Model Parameters and Anti-Slosh Baffle Designs of Propellant Tanks by Using Lateral Slosh Testing

The slosh dynamics of propellant tanks can be represented by an equivalent pendulum-mass mechanical model. The parameters of this equivalent model, identified as slosh model parameters, are slosh mass, slosh mass center of gravity, slosh frequency, and smooth-wall damping. They can be obtained by both analysis and testing for discrete fill heights. Anti-slosh baffles are usually needed in propellant tanks to control the movement of the fluid inside the tank. Lateral slosh testing, involving both random testing and free-decay testing, are performed to validate the slosh model parameters and the damping added to the fluid by the anti-slosh baffles. Traditional modal analysis procedures are used to extract the parameters from the experimental data. Test setup of sub-scale test articles of cylindrical and spherical shapes will be described. A comparison between experimental results and analysis will be presented

Stellar Diameters and Temperatures. I. Main-Sequence A, F, and G Stars

We have executed a survey of nearby, main-sequence A-, F-, and G-type stars with the CHARA Array, successfully measuring the angular diameters of forty-four stars with an average precision of ~1.5%. We present new measures of the bolometric flux, which in turn leads to an empirical determination of the effective temperature for the stars observed. In addition, these CHARA-determined temperatures, radii, and luminosities are fit to Yonsei-Yale model isochrones to constrain the masses and ages of the stars. These results are compared to indirect estimates of these quantities obtained by collecting photometry of the stars and applying them to model atmospheres and evolutionary isochrones. We find that for most cases, the models overestimate the effective temperature by ~1.5%-4% when compared to our directly measured values. The overestimated temperatures and underestimated radii in these works appear to cause an additional offset in the star's surface gravity measurements, which consequently yield higher masses and younger ages, in particular for stars with masses greater than ~1.3 M_☉. Additionally, we compare our measurements to a large sample of eclipsing binary stars, and excellent agreement is seen within both data sets. Finally, we present temperature relations with respect to (B – V) and (V – K) colors as well as spectral type, showing that calibration of effective temperatures with errors ~1% is now possible from interferometric angular diameters of stars

Finite Element Model Calibration Approach for Ares I-X

Ares I-X is a pathfinder vehicle concept under development by NASA to demonstrate a new class of launch vehicles. Although this vehicle is essentially a shell of what the Ares I vehicle will be, efforts are underway to model and calibrate the analytical models before its maiden flight. Work reported in this document will summarize the model calibration approach used including uncertainty quantification of vehicle responses and the use of nonconventional boundary conditions during component testing. Since finite element modeling is the primary modeling tool, the calibration process uses these models, often developed by different groups, to assess model deficiencies and to update parameters to reconcile test with predictions. Data for two major component tests and the flight vehicle are presented along with the calibration results. For calibration, sensitivity analysis is conducted using Analysis of Variance (ANOVA). To reduce the computational burden associated with ANOVA calculations, response surface models are used in lieu of computationally intensive finite element solutions. From the sensitivity studies, parameter importance is assessed as a function of frequency. In addition, the work presents an approach to evaluate the probability that a parameter set exists to reconcile test with analysis. Comparisons of pre-test predictions of frequency response uncertainty bounds with measured data, results from the variance-based sensitivity analysis, and results from component test models with calibrated boundary stiffness models are all presented

Ares I-X Flight Test Vehicle Modal Test

The first test flight of NASA's Ares I crew launch vehicle, called Ares I-X, was launched on October 28, 2009. Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Flight test data will provide important information on ascent loads, vehicle control, separation, and first stage reentry dynamics. As part of hardware verification, a series of modal tests were designed to verify the dynamic finite element model (FEM) used in loads assessments and flight control evaluations. Based on flight control system studies, the critical modes were the first three free-free bending mode pairs. Since a test of the free-free vehicle was not practical within project constraints, modal tests for several configurations during vehicle stacking were defined to calibrate the FEM. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report describes the test requirements, constraints, pre-test analysis, test execution and results for the Ares I-X flight test vehicle modal test on the Mobile Launcher Platform. Initial comparisons between pre-test predictions and test data are also presented

Ares I-X Flight Test Vehicle:Stack 1 Modal Test

Ares I-X was the first flight test vehicle used in the development of NASA s Ares I crew launch vehicle. The Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Three modal tests were defined to verify the dynamic finite element model of the Ares I-X flight test vehicle. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report focuses on the second modal test that was performed on the middle section of the vehicle referred to as Stack 1, which consisted of the subassembly from the 5th segment simulator through the interstage. This report describes the test requirements, constraints, pre-test analysis, test operations and data analysis for the Ares I-X Stack 1 modal test