SAMS-II: Decimation of a Project

Tom SutliffNASA Glenn Research Center

Knowledge SharingFebruary, 2004

Outline

• Project Background• Realities of being an “ISS project”• Cuts: The ‘Big One’• Pain, suffering, and …survival• A new awakening• Conclusion

Project BackgroundSpace Acceleration Measurement System-II

(a 2nd generation system)

• Measures vibratory acceleration disturbances in support of the Microgravity Research Program research experiments (Code UG)– Over a dozen STS and Mir missions were supported

with SAMS• Develop a system for 10+ years of operation on

a Space Station (Freedom, Alpha, ISS, …)

STS ISS

ISS Research- New Era, New Vehicle

• ISS will provide new opportunities for on-orbit research studies

• Microgravity environment is key component being investigated

Desired Research Environment

• Vibratory:– Ranges from

milli-g to sub-µg

• Quasi-Steady:– Below 1 µg

0.1 1 10 100 1000

Frequency (Hz)

0.01

10-5

10-3

Vib

rato

ry

A

ccel

erat

ion

leve

ls (g

/g0)

10-2

10-4

10-7

10-6

10-1

SSP 41000D

Some materials research should be done at this level, but will not be done on ISS.

300

Each line represents a family of experiments

ISS vibratory requirement

Fluid Physics

Low-temperature Microgravity Physics

Materials Science

Combustion Science

Biotechnology

Measure the Environment for Research

• SAMS-II– A vibratory environment measurement system

• 0.01 Hz to 300 Hz; 1 µg to 0.1 g • Multiple sensors distributed to payloads• Centralized control computer• Ground data dissemination• Data analysis and trending

Interim Control Unit RTS (typ)

ISS MRL Network

ISS Downlink Stream

SAMS-II Ground Operations Equipment (at TSC)

Investigator’s Research Site

Internet

SAMS-II Deployments

• Control Unit– NASA EXPRESS Rack

• Remote Triaxial Sensors– EXPRESS Rack shelves– Drawers– Facilities– Locker Payloads

The Customers:NASA Microgravity Science Disciplines

Other research areas (life science, space products)

Vehicle dynamicists

Vehicle Maintenance and � Sustaining Engineering

SAMS for Space StationSAMS-II

• SAMS-II is a modular, distributed architecture acceleration measurement and analysis system

– Control Unit- data storage and analysis– Remote Triaxial Sensors- variable frequency

ranges– Ground Operations- PI command and control

access• Payloads integrate sensors at experiment location

– Digital sensors, programmable frequency ranges• General purpose acceleration measurement system

– Consistent hardware for multiple increments and multiple experiments

– Facility Racks, EXPRESS Racks capability– Provides on-orbit data analysis capability for

experiment decision-making and control• Milestones

– First flight Electronics unit delivered 5/ 99– Flight Control Unit delivered 11/99– On-orbit Operations begin 7 / 00

SAMS-II is a versatile, general purpose acceleration measurement system

But I’m getting ahead of myself...

All is well… or is it?

• Space Station development – A treacherous path

• Payloads are (were) subservient to the vehicle development– Requirements– Budgets

A Typical ISS payload development19991999

DJ F M A M J J A S O N- - - - - - - - - - -20002000

DJ F M A M J J A S O N- - - - - - - - - - -20012001

DJ F M A M J J A S O N- - - - - - - - - - -20022002

DJ F M A M J J A S O N- - - - - - - - - - -20032003

DJ F M A M J J A S O N- - - - - - - - - - -20042004

DJ F M A M J J A S O N- - - - - - - - - - -20062006

J F M A- - -19981998

DO N- - -20052005

DJ F M A M J J A S O N- - - - - - - - - - -

Rev C Assembly Sequence (9/97)Rev C Assembly Sequence (9/97)

Rev D Assembly Sequence (5/98)Rev D Assembly Sequence (5/98)

10/2/98 Assembly Sequence Planning Reference10/2/98 Assembly Sequence Planning Reference

Rev B Assembly Sequence (9/96)Rev B Assembly Sequence (9/96)

OMB Passback (Feb 99)OMB Passback (Feb 99)

9 months9 months

34 months34 months9 months9 months

UF13/99

UF28/99

UF312/00

UF41/01

1J/A6/00

UF59/01

UF6

2/02 11/02

UF75A

USL

Com

bust

ion

Rac

k (C

IR)

ARISC

ore

Rac

k (S

AR

)ARIS

Flui

dsR

ack

(FIR

)

ARIS

5A

USL

UF1

1/00

UF23/00

UF39/01

UF41/02

UF56/02

UF6

8/03 10/03

UF7CAM 16A

12/03

FIR

ARIS

CIR

ARIS

SAR

ARIS

5A

USL

UF1

4/00

UF28/00

UF32/02

CIR

ARIS

UF45/02

UF59/02

FIR

ARIS

11/03

UF7CAM 16A

1/04

SAR

ARIS

5 months5 months

3 months

3 months1 month1 month

5A

USL

UF1

11/00

UF23/01

UF310/02

CIR

ARIS

UF411/02

UF56/03

FIR

ARIS

17A9/03

UF6

4/04 5/04

UF7CAM 16A

7/04

SAR

ARIS

8 months8 months 9 months

9 months6 months6 months

Rev E Assembly Sequence (6/99)Rev E Assembly Sequence (6/99)

UF12/99

UF26/99

UF38/00

UF41/01

1J/A1/00

UF58/01

UF6

1/025A

USL

Com

bust

ion

Rac

k

ARIS Cor

e R

ack

ARIS Flui

ds R

ack

ARIS

6-30 SSAIT Approved Assembly Sequence (6/94)6-30 SSAIT Approved Assembly Sequence (6/94)

8 months8 months18 months18 months

5A

USL

UF1

1/01

UF25/01

UF32/03

CIR

ARIS

UF45/03

UF59/03

FIR

ARIS

17A3/04 8/04

UF7CAM

SAR

ARIS

4 months4 months

3 months

3 months23 months23 months

LF-?

4/06

UF6

9/04

16A

11/04

Changes in FCF Deployment due to Assembly Sequence Revisions, OMB Passback & POP 99-1

Final POP 99-1 MarksFinal POP 99-1 Marks POP 99-1 Marks

CIR: 18 mo. push (2 yr. Period)

9 mo. push (1 yr. Period)

5 mo. push (9 mo. Period)

4 mo. push (9 mo.)

8 mo. push (5 mo.)

SAMS-II Redirection Realities

• ISS-budget driven SAMS-II project constraints– traffic model (customers and timing)– Budget– scope... Realities-->

• ISS Problems ($500M over budget, facilities delay)– SAMS-II budget bar chart

• What it means for SAMS-II ...

(from All-Hands charts on 10/11/96)

Decimate the project

SAMS-II Redirection Realities (10/96)

What it means for SAMS-II ...• CLOSE-OUT ALL NON-RTS RELATED WORK

– CU redesign efforts to be documented and closed out– CU related procurements stopped– Q-SICA effort is stopped– GOE designs and procurements to be put on hold– CU-GSE efforts stopped– CU, GOE, CU-GSE Software, RFAs, design put on hold

• EXCEPTIONS: – Complete the MSS Thermal POC evaluation– Complete the Coldplate fabrication capability development study– ISSUES: Long lead VME procurement must be assessed– Other?

SAMS-II Redirection Realities (10/96)

What it means for SAMS-II ...

• CONTINUE RTS WORK– Demonstrate the RTS functionality (boot, configure, collect and transmit

data) using the Engineering Model hardware RTS– Develop and test at qualification levels an RTS system– Develop and test flight RTS systems to support user requirements– Support flight hardware deliveries to EXPRESS Rack (flight RTS-EEs: 2

at 1/97, 2 at 4/97)– Develop the support systems later (CU, GOE) that allows usage of the

RTS as provided• Will require early creation of key functional elements of CU, GOE to ensure

adequate checkout of RTS functions

BUT

SAMS-II Redirection Realities (10/96)

What it means for SAMS-II ...• OTHER APPROACHES TO BE CONSIDERED BY PROJECT/ BY

MANAGEMENT:– Eliminate a CU configuration (either Eng. Model or Qualification Unit) to

decrease program cost and still maintain a FY01 ship date– Redefine SAMS-II operational configuration (eg. a more independently

operating RTS capability)– Change project operating paradigm (fast-track, different controls and

reporting methods, all civil servant implementation team, additional risk acceptance)

• Alternate funding sources- partnering with NASDA, partnering with AMES/Centrifuge project (a sharing of development costs as well as recurring costs for hardware to be provided)

• Open to suggestions on creative ideas to save money, decrease complexity, do more with less, accomplish the same functions with less development costs

… A core system

GSE Laptop

Remote Triaxial Sensor

Electronics Enclosure

Sensor Enclosure

Remote Triaxial Sensor

• Implementation Approach– Distributed measurement system (multi-user)– Minimize sensor head size (RTS-EE + RTS-SE)

– Maintain performance• Status

– CDR 4/97; Phase 1/2 Safety Review 12/97– Qual Unit completed testing 6/98– Prepare EE Flight Unit #1 to Ship to EXPRESS

Remote TriaxialSensor System

GSE / Interim Control Unit• Implementation Approach

– Rely on existing ISS Laptop (PCS) hardware heritage– Deploy SAMS-II-specific software in Laptop for RTS

operations– House components in a standard ISIS drawer

• Status– Prel. Design Review (engineering model)– Flight unit shipment planned for 11/99.

ICU Components

Power Control Box

Air inlets (both sides)

PCS Laptop(on slides)

Fan and FilterISIS- PoweredDrawer

- custom- standard

ICU Components

• ISIS Drawer (ISS standard)

• ThinkPad 760XD Laptop (ISS standard)

• Power Control Box (PCB)• Fans (Drawer & PCB)• Circuit Breakers• Designed with Military and Industrial

Electronics for Reliability

Interim Control Unit

Remote TriaxialSensor System

Flight Unit #1

More with Less...

• Upon approval of the approach SAMS-II was solicited to provide support to:– First Fluid Physics Experiment (EXP-PCS)– A vehicle Risk Mitigation Experiment (ARIS-

ICE), – The Microgravity Science Glovebox, and – General vehicle characterization… – And others…

S-II ISS Traffic_Rev_D(5-98)Acceleration Measurement Program

ISS Traffic ModelCurrent Scope (SAMS-II)

BASELINE

Interim Control Unit

Control Unit

Remote Triaxial Sensors

EXPRESS Rack EE

SE (PCS) (TBD) (TBD) (TBD)

Fluids & Combustion EEFacility

SE

Material Science EEResearch Facility

SE

Glovebox (MSG) EE

SE

Biotechnology Facility (BTF) EE

SE

Low Temperature EEMicrogravity PhysicsFacility (LTMPF) SE

UF 14/00

UF 28/00

UF 32/02

UF 59/02

1E10/02

17A11/02

HTV22/03

UF 68/03

UF 710/03

Future

(7/04)

S-II ISS Traffic_Rev_D(5-98)Acceleration Measurement Program

ISS Traffic ModelAdded Scope (SAMS-II)

1E10/02

17A11/02

HTV22/03

UF 68/03

UF 710/03

Future

OPPORTUNITIES

MAMS

Remote Triaxial Sensors

ARIS RME EE (2)

SE (3)

EXPRESS Rack EEGround Simulator

SE (2/99)

Multi Phase Flow and EETransport Facility(MPFTF) SE

NASDA EE (4)

SE (5) (8-10/01)

(2005)

UF 14/00

UF 28/00

UF 32/02

UF 59/02

And we did it!

• SAMS-II system elements were successfully launched aboard STS-100 (ISS flight 6A), April, 2001.

• First data was acquired and downlinked on June 5, 2001

• SAMS-II has accumulated over 16,000 hours of on-orbit operational time and data.

ICU (on orbit, in EXPRESS 4)

SAMS RTS-D onboard ISS(10_01).JPG

RTS-Drawer (on orbit)

First SAMS-II Data (June 5, 2001)1st_S-II Data_Graph.jpg

Key Points• Communicating bad news can be done.

– Projects and people are resilient. • Focus on what is still viable.

– Teams just need a little positive reinforcement to remind them that the glass usually half full.

• Remember that change usually has a positive element, too.

• SAMS-II was destined to be a success.– Success comes in many forms.

Epilogue

• And as is typical of success stories, I was promoted.– So, on to my next challenge...

�Combustion Science Program(my next challenge)

• Science – Fundamental research

• Flight Projects – To conduct the investigator’s science

Combustion Science on ISS

Combustion Payloads

Multi-User DropletCombustion Apparatus

ISS US Lab Module

Combustion Experiment inFluids and Combustion Facility

Combustion Chamber

Multi-User Solid FuelCombustion Apparatus

Cool FlamesCombustion Investigation

SIBALFIST TIGER-3DREEFSATHINASTF-Pello

Commercial/ International Partner Apparatus

Water MistCatalytic Comb.Hi-Pressure

Multi-User GaseousFuel Combustion Apparatus

V-FlameFlame DesignS-FlamesPUFF

Principal Investigator (PI)Droplet Combustion

Experiments

BCDCEDCE-2

SEDC DDCE

Combustion Experiment in the

Microgravity Science Glovebox

SmokeSPIDERSALSA

2 Facilities, 15 PIs,3 partner investigations, Future research capability

An Annihilation of the Program Content(~2001)

But that’s another story.

Backup Information

SAMS-II: Decimation of a Project (how to save a project)

(and build a team)(and surpass expectations)

(and garner new customers)

SAMS-II History• SAMS-II initiated in 1991• Requirements gathered from UG disciplines• Architecture defined CU, multiple RTS

– System Hardware PDR held 11/95

• CU delayed (10/96), ICU concept developed • RTS proceeding towards multiple deliveries

– RTS CDR held 4/97; status of RFAs

• Operations to begin at 6A (4/00) [rev Rev D]

11/18/98 T. Sutliff 4