The European Space Agency (ESA) and their prime contractor Airbus Defense Space (ADS) are developing the European Service Module (ESM) for integration and utilization with other modules of NASAs Orion Multi-Purpose Crew Vehicle. As part of this development, ESA, ADS, NASA and the Lockheed Martin Company performed a series of reverberant acoustic tests in April-May 2016 on the ESM Structural Test Article (E-STA), the mechanical mock-up of the ESM designated for mechanical tests. Testing the E-STA under acoustic qualification loads verifies whether it can successfully withstand the medium and high frequency mechanical environment occurring during the vehicles lift-off and atmospheric phases of flight. The testing occurred at the Reverberant Acoustic Test Facility (RATF) at the NASA Glenn Research Centers Plum Brook Station site in Sandusky, OH, USA. This highly successful acoustic test campaign excited the E-STA to acoustic test levels as high as 149.4 dB Overall Sound Pressure Level. This acoustic testing met all the ESA and ADSs test objectives, including establishingverifying the random vibration qualification test levels for numerous hardware components of the ESM, and qualifying the ESMs Solar Array Wing electrical power system. This paper will address the test objectives, the test articles configuration, the test instrumentation and excitation levels, the RATF site and capabilities, the series of acoustic tests performed, and the technical issues faced and overcome to result in a successful acoustic test campaign for the ESM. A discussion of several test results is also included.

/pdf/overview-of-the-acoustic-testing-of-the-european-service-3mlr7zkp8b.pdf

Overview of the Acoustic Testing of the European Service Module Structural Test Article (E-STA)

The filter wheel (FW) assembly (FWA), developed by the CBK Institute, is one of the critical subsystems of the wide field imager (WFI) instrument on board the Advanced Telescope for High Energy Astrophysics—mission of the ESA Cosmic Vision 2015-25 space science program (launch scheduled around 2035). The instrument has to collect soft x-rays with very high quantum efficiency, thus WFI requires extremely thin optical blocking filter (OBF). Due to its thickness (∼150 nm) and large area (∼170 mm × 170 mm) needed to achieve a 40 ′ × 40 ′ instrument field of view, the filter is extremely vulnerable to acoustic loads generated during Ariane 6 rocket launch. On the other side, FW mechanism has to provide high overall reliability, so it is more favourable to launch the instrument in atmospheric pressure (without vacuum enclosure for filter protection). Design efforts of the FW subsystem were focused on two issues: providing maximal possible sound pressure level suppression and smallest possible differential pressure across the OBF, which should prevent filters from damaging. We describe the design of a reconfigurable acoustic-demonstrator model (DM) of WFI FWA created for purposes of acoustic testing. Also, the acoustic test campaign is described: test methodology, test criteria, and results discussion and its implication on future FWA design. In general, tests conducted with the FWA DM showed that current design of WFI is feasible and the project can be continued without introducing a vacuum enclosure, which would significantly increase system complexity and mass. 

/pdf/design-and-acoustic-tests-of-the-athena-wfi-filter-wheel-1qrhv4ew.pdf

Design and acoustic tests of the ATHENA WFI filter wheel assembly development model towards TRL5

The NASA Orion Multi-Purpose Crew Vehicle (MPCV), comprised of the Service Module, the Crew Module, and the Launch Abort System, is the next generation human spacecraft designed and built for deep space exploration. Orion will launch on NASAs new heavy-lift rocket, the Space Launch System. The European Space Agency (ESA) is responsible for providing the propulsion sub-assembly of the Service Module to NASA, called the European Service Module (ESM). The ESM is being designed and built by Airbus Safran Launchers for ESA. Traditionally, NASA has utilized reverberant acoustic testing for qualification of spaceflight hardware. The ESM Structural Test Article (E-STA) was tested at the NASA Plum Brook Stations (PBS) Reverberant Acoustic Test Facility in April-May 2016. However, Orion is evaluating an alternative acoustic test method, using direct field acoustic excitation, for the MPCVs Service Module and Crew Module. Lockheed Martin is responsible for the Orion proof-of-concept direct field acoustic test program. The E-STA was exposed to direct field acoustic testing at NASA PBS in February 2017. This paper compares the dynamic response of the E-STA structure and its components to both the reverberant and direct field acoustic test excitations. Advantages and disadvantages of direct field acoustic test excitation method are discussed.

/pdf/examination-of-the-structural-response-of-the-orion-european-45k2t69zjn.pdf

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing

Abstract. The filter wheel (FW) assembly (FWA), developed by the CBK Institute, is one of the critical subsystems of the wide field imager (WFI) instrument on board the Advanced Telescope for High Energy Astrophysics—mission of the ESA Cosmic Vision 2015-25 space science program (launch scheduled around 2035). The instrument has to collect soft x-rays with very high quantum efficiency, thus WFI requires extremely thin optical blocking filter (OBF). Due to its thickness (∼150  nm) and large area (∼170  mm  ×  170  mm) needed to achieve a 40  ′    ×  40  ′   instrument field of view, the filter is extremely vulnerable to acoustic loads generated during Ariane 6 rocket launch. On the other side, FW mechanism has to provide high overall reliability, so it is more favourable to launch the instrument in atmospheric pressure (without vacuum enclosure for filter protection). Design efforts of the FW subsystem were focused on two issues: providing maximal possible sound pressure level suppression and smallest possible differential pressure across the OBF, which should prevent filters from damaging. We describe the design of a reconfigurable acoustic-demonstrator model (DM) of WFI FWA created for purposes of acoustic testing. Also, the acoustic test campaign is described: test methodology, test criteria, and results discussion and its implication on future FWA design. In general, tests conducted with the FWA DM showed that current design of WFI is feasible and the project can be continued without introducing a vacuum enclosure, which would significantly increase system complexity and mass.

https://www.spiedigitallibrary.org/journals/Journal-of-Astronomical-Telescopes-Instruments-and-Systems/volume-9/issue-2/024002/Design-and-acoustic-tests-of-the-ATHENA-WFI-filter-wheel/10.1117/1.JATIS.9.2.024002.pdf

The Flexible Lunar Architecture for Exploration (FLARE) is a concept to deliver four crew to the lunar surface for 7 to 14 days and then return them safely to Earth by 2024. This meets NASA’s internal 2024 lunar landing deadline directed by President Trump (Trump, 2017) and the “5-year” goal set forth by Vice President Pence (Pence, 2019). FLARE is an alternative to NASA’s Human Landing System reference architecture from the Design Analysis Cycle (DAC) #2 (NASA, 2019b). The minimum FLARE concept uses one Space Launch System launch, one Orion, one European Service Module (ESM), and one human lander to deliver four crew to the Moon for a minimum surface duration of 7 days and return them to Earth. FLARE adds a new capability, called the SpaceTug, based upon the mature and successful United Launch Alliance “Common” Centaur Upper Stage vehicle, with modifications. In FLARE, the SpaceTug provides propulsion needed to return the Orion+ESM from the Moon to Earth. The SpaceTug also provides propulsion to deliver the human lander Descent Element (DE) and Ascent Element (AE) separately to lunar orbit. The Orion+ESM then completes a rendezvous with the mated DE+AE in lunar orbit. FLARE also offers optional phases to the Moon 2024 mission. The SpaceTug can also deliver components of the planned Gateway - including the Power and Propulsion Element and the Habitation and Logistics Outpost - to lunar orbit; however, the planned FLARE destination is a Low Lunar Frozen Polar Orbit unlike the NASA DAC2 plan for a Near Rectilinear Halo Orbit. FLARE also provides an option to deliver precursor equipment - including a habitation module, crew mobility devices and an In-Situ Resource Utilization demonstration - to the lunar surface for enhanced crew exploration and science with the extended 14-day surface mission.

/pdf/the-flexible-lunar-architecture-for-exploration-flare-c8wismlb3o.pdf

The Flexible Lunar Architecture for Exploration (FLARE): Designed for the Artemis-3 Moon 2024 Mission and Beyond

This paper presents an overview of the Second European Service Module (ESM-2), the second in a series of European Service Modules produced as part of the Barter agreement between NASA and ESA for the Orion Program. The European Industrial consortium is led by the ESA prime contractor Airbus Defence and Space in Bremen. ESA and Airbus signed the ESM-2 contract on 16 February 2017, for this key element of the Orion Exploration Mission 2 (EM-2). EM-2 is the first crewed mission for Orion and will take astronauts farther into the solar system than humanity has ever travelled. EM-2 will also be a historic mission for Europe, as the ESM-2 will be the first European spacecraft to be part of a human transportation system carrying humans beyond low Earth orbit. ESM-2 is mainly a recurring production following ESM-1. Nevertheless, there are a number of important changes being implemented, for example, to incorporate upgrades to further enhance safety and reliability. The challenging delivery schedule for ESM-2 has driven the need to commence manufacturing prior to completion of the qualification on ESM-1. In addition, some requirement deviations and non-compliances approved for ESM-1 have resulted in modifications for ESM-2. In order to manage the competing constraints effectively, the ESM-2 Team has put in place a number of novel approaches to manage schedule, risk, and technical changes. Airbus has set up multi-functional teams according to an approach known as "Major Spacecraft Deliveries" consisting of quality assurance, engineering and procurement. The risk of starting manufacturing prior to qualification is managed through a special risk share agreement. This agreement necessitates rigorous risk reviews across the board for all manufacturing, assembly, integration and test milestones. The ESM-2 changes are managed by Configuration Management, but Airbus has also introduced the Technical Baseline Matrix to provide a transparent top-level overview of the changes from ESM-1 to ESM-2. The tool provides the basis for ESM-2 design and development needs, decisions, as well as the input for the Orion EM-2 Critical Design Review (CDR). The main technical evolutions, status of the production and the novel management approaches for ESM-2 are presented and discussed in the paper.

https://ntrs.nasa.gov/api/citations/20180007196/downloads/20180007196.pdf

The Second European Service Module (ESM-2) Evolutions, Production and Challenges

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Overview of the Acoustic Testing of the European Service Module Structural Test Article (E-STA)

The Second European Service Module (ESM-2) Evolutions, Production and Challenges

Examination of the Structural Response of the Orion European Service Module to Reverberant and Direct Field Acoustic Testing