Wireless Sensor Systems for Near-term Space Shuttle Missions Kevin Champaigne, Program Director, Invocon, Inc., 19221 I-45 South, Suite 530, Conroe, TX 77385 ABSTRACT NASA has developed a series of wireless data acquisition and communications systems for monitoring critical areas of the Shuttle during pre-flight, ascent, on-orbit, and re-entry phases. Wireless sensor and data logger applications include monitoring the structural dynamics of payloads, collecting data for modal analysis of the flexhose assemblies, and measuring strain on both the Main Engine struts and the Remote Manipulator System (Shuttle Arm). Additionally, the Wing Leading Edge Impact Monitoring System is being installed within the Shuttle wings for the Return to Flight mission, STS-114, and subsequent missions to assist in detecting, locating, and characterizing the severity of impact events similar to the debris impact that caused the Columbia disaster. In fact, wireless systems based on Invocon’s line of MicroWIS sensors have been developed to investigate or mitigate all three of the latest technical causes of Shuttle launch delays. Each battery operated unit interfaces with various sensors and records data in internal memory for use by analysts post-flight, while some systems perform local detection algorithms and transfer data through Shuttle data systems for analysis by ground personnel during the mission. Through the use of a basic system design with considerable flight history and through the limiting of interfaces with Shuttle resources, the development time and cost, as well as integration effort for installation, have been significantly reduced, enabling the use of the systems for the first or second flights. The general design of the systems are discussed in this paper, including sensor interfaces, hardware design, embedded software algorithms, system operations, and Shuttle integration methods. BACKGROUND As part of the Columbia Accident Investigation Board (CAIB) recommendations following the Columbia disaster, significant recertification of many major Shuttle systems has been undertaken in order to verify that the Shuttle is as safe as reasonably possible. Discrepancies between the certified usage and environmental limits of various systems and the actual limits experienced during flight are of major concern. However, sensor data to define the actual ground processing, launch, on-orbit, and landing stresses and environments is often limited, leading to overly conservative models. As such, retrofit instrumentation has been requested by a number of organizations for flight measurements, as well as during Shuttle processing activities. The integration of such a large number of new sensors into existing Orbiter instrumentation resources likely would have been prohibitively expensive, cause an excessive increase in vehicle launch weight, and potentially cause significant launch schedule delays. Alternatively, the Shuttle Program has chosen to utilize a variety of stand-alone, autonomous, miniature data acquisition systems based on Invocon’s Micro-miniature Wireless Instrumentation System (MicroWIS) concepts and previous flight developments which minimize the level of vehicle resources or modifications required. Through the use of flight-proven wireless instrumentation technology developed through a partnership with Johnson Space Center and Invocon, Inc., battery operated systems either have already been fully developed or are currently under development for flight applications aboard one or more of the first three Shuttle flights after the Columbia disaster. The MicroWIS technology flight applications have been very successful and have enabled the beginning of a “peel and stick” sensor installation paradigm that promises to revolutionize miniaturized sensor installations on complex systems. These include wireless sensors that can either record or transmit temperature, triaxial accelerometer, strain, pressure, tilt, chemical, and ultrasound data. Over 19 NASA missions have included Invocon wireless instrumentation products comprised of 12 unique hardware designs. The miniature, wireless instrumentation and sensor products can enable a 10X reduction in the integration and installation costs for the Shuttle and ISS compared to traditional retrofit wired approaches. Wireless, battery-operated, intelligent sensors, some less than 1 cubic inch, are easily bonded to vehicle structure and monitor environmental parameters, enabling real-time monitoring of critical items and providing inexpensive data for model validation. MicroWIS-based Extended Life MicroWIS-based MicroTAU-based Wideband MicroTAU-based Sample Rate Up to 1Hz Up to 1Hz Up to 500Hz Up to 20,000Hz Data Storage 2Mbytes & Real-time Transmission 1Mbyte 256Mbytes Local Data Processing Real-time Transmission to PC Only No No Battery Life 9 months 10+ years Sensors Resistive sensors including Temperature, Strain, Accelerometer, Pressure Resistive sensors including Temperature, Strain, Accelerometer, Pressure Yes 8bit micro-controller 50 hours of data acq. 1 year sleep mode Resistive or Voltage sensors including Strain, Accelerometer, Pressure Yes High-speed DSP 80 hours of data acq. 5 years sleep mode Piezoelectric including Accelerometer or Pressure Flight History 8 Shuttle Flights Flight Certified – awaiting 9 Shuttle Flights first flight on Shuttle Orbital Maneuvering System Flight Certified – awaiting first flight on next mission STS-114 Table 1. MicroWIS Family System Characteristics NEAR-TERM SHUTTLE APPLICATIONS The following applications for various Shuttle instrumentation tasks using wireless sensors and data loggers are either delivered, under development, or approaching final approval by the Shuttle program for near-term flights. Many applications use similar technologies, but take advantage of unique implementations to customize the system for the particular requirements of the system. For each application, the unique portions of the circuit design that enables the system to meet the requirements are explained in detail, although most design concepts apply to multiple systems described below. Main Engine Flowliner Crack Investigation During the summer of 2002, significant launch delays were caused by cracks found in the Space Shuttle Main Engine (SSME) flowliners, which are part of the piping used to supply liquid hydrogen to the engines. The Space Shuttle Program funded the development and application of the Wide-band Micro-Wireless Triaxial Accelerometer Unit (WB MicroTAU) in order to measure the vibration environment experienced by the flowliners during launch. This data will be used to verify the hypothesis of high cycle fatigue as the cause of the cracks found, and potentially as verification of the environmental requirements of replacement hardware. Figure 1. Photographs of Cracks Found in SSME Flowliners (NASA Photo) The understanding of how the dynamic behavior of the SSME feedines and SSME low pressure turbo-pump work together with the pumping fluid to produce cracks in certain areas is critical to continuing flying the Space Shuttle and to the potential redesign of these components. The WB MicroTAU is intended to take triaxial accelerometer data on and about the SSME LH2 and LO2 feedlines and their supporting brackets. Units have been installed on both Discovery and Atlantis vehicles, and are awaiting the first flight of the system. The upgrade of the original MicroTAU system provided nearly a 2-order of magnitude increase in analysis bandwidth and data storage capability. The new system was designed, manufactured, qualified for flight, and installed within just 4 months. System enhancements included: 20K samples/second 128Mbyte Flash memory External cryogenic piezoelectric accelerometers USB interface for faster downloads post-mission Due to the extreme vibration and thermal environments of the flowliners, the data recorders were mounted a short distance from the cryogenic transducer locations. Integration and installation of the system into the orbiters was simplified by the fact that there were no power or data interfaces to Shuttle systems. The system is programmed via RF communication prior to launch to monitor the accelerometer inputs near the scheduled launch time for a vibration signature indicative of launch. When detected, the system will store both pre-trigger and post-trigger data into a large non-volatile memory for the entire launch to orbit phase. Figure 2. Exploded view of Wideband MicroTAU. Each unit is a multiprocessor system with a Network Communication board, a Digital Signal Processor board, a front-end Data Acquisition board, and a patch antenna. The system block diagram is shown in the following figure: ANTENNA RTD NETWORK MODULE DSP MODULE DATA ACQUISITION MODULE Channel 1 Channel 2 Channel 3 3.6V USB INTERFACE Figure 3. Block Diagram of Wideband MicroTAU Sensor Unit Rollout Instrumentation Although the maximum speed of the crawler during Shuttle Rollout is only 1mph, significant structural modes may be excited, potentially damaging Shuttle elements or systems. A pair of wireless triaxial accelerometers will be used to supplement wired ground data acquisition systems to monitor the element interfaces and major modes in the frequency range of roll-out. Recording of accelerations in a triaxial configuration throughout Rollout is desired, with the frequencies of interest ranging from 0.3Hz up to 50Hz. The use of the basic design of the Enhanced Wideband Micro-Triaxial Accelerometer Unit (EWB MicroTAU) is planned, as shown below in Figure 5, but the accelerometers will be mounted internal to the unit rather than external. The wireless triaxial accelerometers will be used to instrument the Orbiter Lift points at the 582 bulkhead on both the port and starboard sides. A series of wired accelerometers and strain gauges will be used to complete the instrumentation suite. These sensors, located inside the payload bay, will have cables routed through the aft bulkhead and out of the vehicle through the aft compartment. These signals will be acquired by a standard data acquisition system located on the Mobile Launch Platform. Data Acquisition Capabilities Figure 4. Shuttle During Rollout (NASA Photo) The EWB MicroTAU Remote Unit is a small, battery-powered, autonomous, wireless device designed for trigger initiated acquisition and recording of acceleration data. The units interface with three accelerometers, and each unit can be programmed for a triggered acquisition event. Download and event setup commands are issued either wirelessly or through a standard USB connection from a Graphical User Interface running on a PC. Each unit contains 256Mbytes of non-volatile memory, which provides for over 20hrs of data recording at 500 samples per second. Additionally, various trigger modes and on-board processing algorithms allow the user to configure the unit to capture and store only interesting data over an even longer period of time. MEMS accelerometers featuring low-power operation and resolution in this frequency band of better than 1mg will be packaged within the enclosure, along with the circuit boards, battery, and antenna for a fully self-contained package. Figure 5. Enhanced Wideband MicroTAU Synchronization with External Data Acquisition System 582 Location (Lift Point) MicroWIS Base Station Ground Data Acquisition System IRIG-E Time Generator Figure 6. Rollout Instrumentation Configuration The synchronization capabilities of the existing Kennedy Space Center data acquisition system are based upon an IRIG-E time generator. The IRIG-E waveform will be simultaneously provided to both the ground data acquisition system and a MicroWIS base station unit. The MicroWIS base station will record this waveform in non-volatile memory while also serving as the master unit for synchronizing the two triaxial accelerometer units via RF communication. This will provide a high level of synchronization between the different data systems following a simple post-processing routine to synchronize the digitized data samples. During data acquisition mode, the sensor units provide a means for synchronizing the acquisition of each data sample between multiple wireless sensors to within ±4µs. This level of synchronization should easily meet the requirements for analyzing the low frequency modes of interest. Sensor units can be configured as master units or slave units. When in master mode, the unit will transmit a synchronization message that is used by the slave units to synchronize the acquisition of the data samples. During a given acquisition, a slave unit will only listen to one master unit for synchronization. Environmental Control Life Support System (ECLSS) Flexhose Analysis In order to assist in the determination of the root cause of a recent leak in the oxygen and nitrogen flexhoses of the Shuttle Environmental Control Life Support System (ECLSS), which caused a launch delay for STS-113, the Space Shuttle Program requested a modified version of the WBMTAU. The modified system provides the sophisticated scheduling, data processing, and memory capacity necessary to obtain all relevant data during the following ground processing and flight events w/o battery replacement: • • • • • Roll-over from the Orbiter Processing Facility (OPF) to the Vehicle Assembly Building (VAB); Lifting and stacking operations in the VAB; Rollout to the Launch Pad; Launch and ascent, and Reentry and Landing Reverse bending fatigue was identified as a possible failure mechanism by system engineers. However, available flex-hose vibration data did not support efforts to resolve the root cause of the OV-105, STS-113 ECLSS flexhose failure. To address the concern that certification tests may not have adequately represented current processing and flight environments, the MicroWIS system was developed to obtain actual processing and fight vibration data both on the flexhoses themselves and the bulkheads on which they were mounted. Through analysis of actual flight data, the Limited Life placed on vehicle Flexhoses may be relaxed from the current limit of 4 flights. Single Axis Accelerometer Triaxial Accelerometers Figure 7. ECLSS Flexhose Installation Location and Sensor Placement Advanced Trigger Mechanisms and Scheduling Capabilities The ability of a stand-alone system to meet all of the desired data acquisition requirements for monitoring the flexhoses through many phases of processing and flight was made possible through a number of advanced triggering and scheduling techniques implemented for this system. A trigger is any event that can cause the software embedded in the unit to change mode and begin performing a new function. For the Flexhose system, a trigger can be any of the following: Time The unit can automatically change data acquisition modes based on GMT time. For example, the unit can start and stop data recording at programmed times when Roll-out is scheduled to occur. RF Commanding The unit can change modes immediately based on a command from the laptop via RF communication. For example, the user may wish to stop a data acquisition manually if the Rollout is delayed. Primary Sensor Channel Data Signature The unit can monitor the primary accelerometer channels and trigger if a user defined number of data samples occur above a programmable threshold. This mode can be used to detect both launch and landing events. Auxiliary Pressure Sensor Since Reentry can be at various times, anywhere from a couple days after launch if there is a problem to 16 days for a full mission, a low-power method to detect it was needed. A low-power pressure transducer is sampled once per minute to detect the change from 0psi to 2psi, which is indicative of reentry into the atmosphere. The units were also programmed to perform a large number of unique events, which can all be programmed at one time pre-launch. The units can be programmed with up to 32 unique Event Acquisitions, and each event can have a conditional branch to specify the next event. Such a flow-chart based programming sequence enables the system to handle multiple launch slips without having to be reprogrammed, among other possibilities. The unit will change the next data acquisition event executed based on whether the launch trigger event was successful or not successful. RF Commands: Start Time Trigger Setup Etc. • • • • • Program launch time Detect Launch through signal analysis of Accel/Strain Record Pre- and PostTrigger data • • • • • RF or GMT Trigger for Roll-over or Roll-out Record up to 10 hours of raw data Optionally process and reduce data Figure 8. ECLSS Example Mission Profile Program de-orbit time Detect Pressure Trigger at low rate Detect Landing through signal analysis of Accel Record Pre- and PostTrigger data Shuttle Remote Manipulator System Instrumentation A Wireless Strain Gauge Instrumentation System (WSGIS) is planned to be used to monitor the structural loads that occur within the mechanical arm portion of the Shuttle Remote Manipulator System (SRMS) during flight operations in which the arm is being maneuvered. The instrumentation system will monitor RMS structural loads through the measurement of RMS material strain at three locations (cross sections): the Shoulder, Elbow and Wrist Pitch/Yaw/Roll Electronic housings as shown below. At each electronic housing location, four full stain gauge bridges will be bonded to the electronics housing structure to measure the following parameters: 1. Bending Moments in two orthogonal planes 2. Torsion 3. Axial Force A wireless unit will be mounted to the RMS at each electronics housing location. The avionics boxes will provide excitation and conditioning for 4 separate strain gauge circuits, analog to digital conversion of strain gauge outputs, data processing with stop/start capabilities, data logging in 256Mbytes of non-volatile memory, batteries, and a wireless radio frequency interface via an external antenna. At the desired sample rate of just 50Hz, there will be sufficient battery power and memory to acquire up to 120hrs of raw data from all four channels. The avionic boxes will be mounted at each location under the existing RMS thermal blankets. Each unit will have an external antenna, which will be connected to the avionics box and will protrude beyond the outer surface of the thermal blanket. The system will function as a master/slave system with the synchronization of the data between avionic boxes maintained via a synchronization signal sent from the master unit to each of the slaves. Start and stop of data acquisition is initiated via signals received via RF. Control of the system will be conducted from a laptop located on the aft flight deck of the shuttle by a member of the Crew. The laptop has a wired interface to a Receiver Assembly, which will be located in the aft flight deck payload bay window. All strain data will be stored within the units for post flight collection via a wired USB connection. As an add-on to the current design concept, a forth unit has been discussed in order to measure loads induced by the EVA crew member on the Arm at the Articulating Portable Foot Restraint (APFR), to which the crew member is secured to the end of the Arm. Crew Transmitter& Receiver PGSC Aft Flight Deck PLB Window Figure 9. System Configuration of Shuttle RMS Wireless Strain Gauge System Wing Leading Edge Impact Detection and Location System The cause of Columbia accident has been determined to be foam debris from the External Tank left bipod ramp impacting and damaging the portside wing leading edge Reinforced Carbon Carbon (RCC) panels during ascent of STS-107. Ground-based cameras captured imagery of the impact, but were not able to reliably characterize the location or severity of the foam impact and resulting damage. No sensors existed on the vehicle that would enable ground personnel to determine the extent or location of damage. As part of the Columbia Accident Investigation Board (CAIB) recommendations, monitoring of the Orbiter wing leading edge during ascent is now a requirement for all future Shuttle missions. Although this can be accomplished with improved ground based imagery and on-orbit inspections with the Orbiter Boom Sensor System, the Shuttle Program decided to implement an accelerometer based impact detection and location system on the wing leading edges for the Return to Flight (RTF) mission. The purpose of this initial system was to enable ground personnel to place additional emphasis on the on-orbit inspection of particular areas of the wing Thermal Protection Systems based on possible impact data acquired during ascent. In addition to monitoring for foam impacts during ascent, the Wing Leading Edge Impact Detection System will also monitor the RCC panels for Micro-Meteor and Orbital Debris (MMOD) impacts during the on-orbit phase. Due to the limited time and resources available prior to the RTF mission, the decision was made to implement the system in such a way as to minimize the level of vehicle resources or modifications required. Through the use of flight-proven wireless instrumentation technology developed through a partnership with Johnson Space Center and Invocon, Inc., an autonomous, battery operated system has been fully developed and produced, and is currently being tested and installed on the Space Shuttle Discovery for the first mission. Laptop-based Receiver Assembly collects (via radio frequency) data from Relay Unit and dumps data to PC for downlink to Mission Control Relay Units collect (via RF) postprocessed data from Sensor Units and transfer to crew compartment via wired RS-485 multidrop networked bus Sensor Units record and post-process accelerometer and temperature readings during ascent and while onorbit FIGURE 10. System Overview. Sensor Selection and Data Acquisition Requirements Mounting sensors such as accelerometers or acoustic emission (AE) sensors directly on the Wing Leading Edge RCC panels was considered impossible due to the extremely high temperatures experienced on the back side of the panels as well as the reluctance to drill any new holes in the leading edge spar to run cabling. Therefore, instrumenting the back side of the spar was determined to be the optimum solution. Each RCC panel is mounted to the spar through a series of metallic fittings at 4 bolted locations. Since the load path from the RCC to the spar was through these bolts, the area around the bolts was determined to be the location with the highest signal level on the spar. Initial NASA testing during impact testing at Southwest Research Institute showed that relatively low frequency vibrations and strains were transferred through the potentially loose panel fittings. Since the accelerometer signal levels observed during impact tests in the 10 – 5000Hz range were significantly above nominal flight background levels during ascent, accelerometers were selected as the baseline sensor for the Return to Flight mission. Investigation by NASA into the use of AE sensors at a higher frequency is, however, still ongoing, and will likely be addressed through the flight of a Development Test Objective (DTO) system to measure AE background levels with modified EWB MicroTAU units. Impact Detection Algorithms Since the amount of data acquired during the 10-minute ascent period is nearly 100Mbytes, the time to download all data, even from a single unit, via the RF link or serial communications link is excessively long. Therefore, in order to utilize the data acquired by the EWB MicroTAU shortly after ascent, data reduction algorithms were required to minimize the quantity of data that must be transmitted via RF. However, care must be taken to not diminish the amount or quality of information contained in the returned data. The existing hardware contains significant processing power in the form of a Digital Signal Processor (DSP) to process the acquired data while expending a minimal amount of battery resources. A variety of algorithms have been identified for feature extraction and data reduction. Most are currently based on the implementation of a sliding window, root-meansquare (RMS) calculation. After the time period of a likely impact is determined, the raw data for both before and after the peak for all channels for that period is downloaded to the laptop in the crew compartment and subsequently downlinked to Mission Control. The following algorithms are available to be executed by the embedded software during the post-ascent data processing phase or any time after data is acquired. It that way, new algorithms or settings can be uploaded to the units while on-orbit and run on ascent data if necessary. ¾ ¾ ¾ Peak G’s The system is able to generate a summary list of the highest raw acceleration values and the associated timestamps to be downlinked. Root Mean Square (RMS) Peaks The system can perform a sliding window RMS calculation on the raw data according to user selected window size, window overlap, and digital bandpass filter frequencies, and then return a summary list of the highest data points. Typically window sizes of 256 samples are used to accentuate the impact events, which typically excite the structure for on the order of 100ms. Relative RMS Peaks The system can also optionally remove the background noise-floor level from the RMS calculation above. This is done by taking another sliding window RMS calculation with a much wider window size and subtracting this background from the narrower window. In this way, varying background noise levels, such as occur throughout ascent due to SRB ignition, etc., can be removed. Examples of these algorithms are shown below as applied to a set of representative data. This data set was created summing actual flight accelerometer data acquired on the Shuttle wing with test data for representative foam impacts acquired during testing. Figure 11. Raw Flight Data Set (Prior to Adding Impact Signals). (a) (b) RMS Peaks Algorithm Results with Impact Signatures Added Relative RMS Peaks Algorithm Results with Impact Signatures Added Figure 12. Multiple Techniques for Identifying Impact Events. Additional Applications Three additional applications using wireless, autonomous sensor devices will also be flown on some or all of the initial three flights. The STS-114 will be the first flight of the Extended Life MicroWIS, which was developed initially for measuring temperature on external portions of the ISS for the life of the vehicle. The C-cell battery will provide for a calculated 17-year life while sampling, storing, and transmitting a temperature sample once per minute. Units will be located within the Orbital Maneuvering System (OMS) pod for temperature monitoring of an OMS engine during all phases of the mission. The MicroTAU system will be making its third flight aboard the Shuttle on STS-114. The original MicroTAU is a network of small, battery powered, wirelessly programmable, tri-axial acceleration data recorders, designed to monitor the relative movements of the Multipurpose Logistics Module (MPLM) payload and the Shuttle sill longeron at the interface trunnion pin. In order to meet this requirement, the MicroTAU units have a wireless data synchronization capability of ±30uS at 250Hz sampling. As part of its eighth mission on Shuttle, Micro-Strain Gauge Units will be used to acquire strain data on each of three thrust structure support beams for the SSME pitch actuators in the aft of the orbiter. The data recording will be triggered on the launch event, and will continue through ET separation (~820 seconds), including 10 seconds of buffered strain data prior to the launch event. Orbiter Structures Division will compare the measured data with certification analyses to extend the limited life of these parts. The Micro-Strain Gauge unit will store. CONCLUSIONS NASA has traditionally used models for predicting various spacecraft performance, remaining life, and environmental parameters, typically using high safety margins and assuming worst case conditions. Through the use of low-cost Invocon wireless sensors and data recorders, actual flight measurements have been made which have enabled NASA to refine models and reduce safety margins effectively. Invocon systems have been used to support an increase the design life of the Shuttle Main Engine Struts, to correlate models of Shuttle payload launch dynamics, and soon to analyze the Shuttle Main Engine flow-liners for high-cycle fatigue-causing vibration and to monitor the Shuttle Wing Leading Edges for impacts from foam, ice, or ablator material during launch. Determining efficient and effective methods for implementing similar retrofit instrumentation functions for the lowest cost in terms of mass, volume, development effort, and installation effort needs to be a NASA priority as it attempts to complete the International Space Station and continue on the Moon and Mars as part of future Exploration programs. Overall, wireless and wired networked sensor/actuator technologies have been recognized by NASA, as well as other space agencies, as being critical for improving spacecraft reliability, reducing spacecraft wire harness weight, and drastically reducing spacecraft development, testing, and life-cycle costs. Invocon has been at the forefront of wireless data acquisition and communication for space applications since the beginning, flying the first automated wireless sensor network in space. Enormous challenges exist with regard to the new Exploration Vision to further reduce size, weight, power, and infrastructure requirements for vehicle and payload sensor systems. Invocon, in partnership with NASA, seeks to build upon the current technology by providing improved bandwidth, communication robustness, temperature range, radiation tolerance, and battery life while minimizing size and mass for systems with highly capable local data processing within self-configuring, self-repairing communication networks. ACKNOWLEDGMENTS The author would like to thank John Saiz, Robert Villarreal, George Studor, and George James of NASA Johnson Space Center, John Coates of Lockheed Martin, and Frank Graffagino of Dynacs, Inc for contributing graphical material for this paper.
© Copyright 2026 Paperzz