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Combining Tools, Tasks, Flight Hardware & Astronauts in Pre-Flight

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Combining Tools, Tasks, Flight Hardware & Astronauts in Pre-Flight The Space Congress® Proceedings 1999 (36th) Countdown to the Millennium Apr 28th, 2:00 PM Paper Session II-B - Combining Tools, Tasks, Flight Hardware & Astronauts in Pre-flight Ground Fit Checks for On-orbit Success Michael E. Haddad NASA Kennedy Space Center Follow this and additional works at: https://commons.erau.edu/space-congress-proceedings Scholarly Commons Citation Haddad, Michael E., "Paper Session II-B - Combining Tools, Tasks, Flight Hardware & Astronauts in Pre- flight Ground Fit Checks for On-orbit Success" (1999). The Space Congress® Proceedings. 12. https://commons.erau.edu/space-congress-proceedings/proceedings-1999-36th/april-28-1999/12 This Event is brought to you for free and open access by the Conferences at Scholarly Commons. It has been accepted for inclusion in The Space Congress® Proceedings by an authorized administrator of Scholarly Commons. For more information, please contact [email protected]. 36th Space Congress April 27 – April 30, 1999 Combining Tools, Tasks, Flight Hardware and Astronaut Pre-Flight Ground Fit Checks For On-Orbit Success by Michael E. Haddad NASA Kennedy Space Center Abstract: Thispaper willdiscuss the processof performing“Fit checks” which refersto matingflight hardware together on the ground before they on-orbit.will be Themated concept seems simple butit can be difficultto perform operations like this on theground when the flighthardware is being designed to be mated on-orbit in a zero-g and/or vacuum environmentAlsosome of sp of the items are manufacturedyears apartso how are fitchecks performedon these components if one piece is on-orbit before its mating piece Bothis planned theInternal to be bu Vehicular Activityand (IVA) Extra-Vehicular Activity (EVA) fitchecks will be presented.Details include; how fit checks should mimic on-orbit operationala seriesof scenarios, photographs will be includedthat were takenduring fit checks performedon InternationalSpace Station(ISS) flight elements and the paper will conclude with lessons learned as a result o 1 Fit Check Definition: Fit check refers to mating two (or more) flight items togetherFitchecks oncan the relate ground. to an electricalcable being mated between firstISS elementUnity and the Laboratoryelement, fluidline being mated between Unityand the Airlock,two piecesof structurebeing mated together like the Ku-band antenna and itsOrbital boom,Replaceable or an Unit (ORU) mounted to its on-orbit location.like ORU’s,batteries or electronicboxes, are itemsthat can be installedon- orbitby theAstronauts/Cosmonauts, or on theground before launch, with the capabilityto be removed/repositioned at a later time as part of normal on-orbitoperations. maintenance Example; ifbattery replacement is necessary, everything possible needs to be done ahead of time to assure this itemcan be removed and replacedwith a good battery.Fit checks help assure this change-out of hardware is successful. Some times flight-to-flightare notpossible, fitso checks master units, which simulate the flight items should bea last used,resort. but All onlyefforts as should be made to use flighthardware. Note: For purposes of this paper, Astronauts/Cosmonauts will be refereed to as the “Crew”. On-orbit Operational Scenarios: The fit checkacts like a dry run forthe actual on-orbit operations that will be performedby the Crew. These operationscould be IVA or EVA relatedwhich are partof the normalassembly sequence of Space Station,partof a contingencyplan regarding repairs for failures on-orbit or off-nominalsequence that is critical to allowing assembly operations to continue.Fit checks of the hardware will usually determine the proper order,events or thatsequence need to of occur. Planningtakes place on what the Crew shoulddo to accomplisha task,and the fitcheck validates the planning. Internal Vehicular Activity (IVA): IVA relates to tasks performedtheCrew by in a shirtsleeveenvironment internal to pressurized Space Station Elements, like Unity, the Laboratoryand Airlock ModuleModule. An IVA taskcould be as simpleas turninga valve,to connecting20+ electricaland fluidlines between ISS elements,or totalactivation of the new ISS elementthat has justarrive on-orbit. IVA taskcan perform by ‘Station Crews”are permanentlythat occupying the Space Stationor Crews aboard vehicles just launched from Earth.tasks Manycan IVA be performedat thesame timebecause the largenumbers of crew members presentinside the pressurizedISS elements. What is criticalto IVA operationsis usuallythe sequence of stepsthat need to be performedand maintaining a certain order of tasks, one-after-another,successful completion.to assure Stand- aloneIVA task are mostlystraightforward, but the problem occurs when IVA tasksare integrated with other operations, like berthing anIVA element pre-flight on-orbit.fitchecks allow the Crew to perform a dry run ofwill whatactually theybe performingin Space usingthe same flight tools, flight hardware and sequence of steps (flightcan procedure). be similarto IVA normal tools used every day here on Earth. Accessrelatively to hardwareeasy and is the flight hardwarecan be designedand operatedvery similarto normalevery day operationson the ground.This allows extra time and resourcesto solveany problemsthat may occurduring the IVA operations.Even withthese similarities to ground operations, fit checks are mandatoryto assure successful operations, because if somethingon-orbit, does notthe only workway to fix it may be to bring it back to the ground, which nobody wants toan do. IVA taskPhoto #1 performed by the STS-88 flight crew during their mission in December 1998. 2 Photo#1 – Bob CabanaSergei & Krikalev are about to open the Unity Forward hatch allowingaccess intothe UnityISS element. Note the flightprocedure being checked to assure proper steps are followed. Extra-Vehicular Activity (EVA): EVA, unlike IVA, is performed out in the vacuum of space. The EVA Crew wears suit containing breathing, pressured & temperature controlled environment. Th the crew can spend EVA do to limited consumables in the suit. Also, special t need to be designed, plus most EVA operations will take place with only two cr thus limiting the number of tasks performed during each EVA operation. The cr some many tools and pieces of hardware. Even though there are toolboxes and lo outside of ISS to mount more tools and hardware the crew only has two hands wi storage locations on the suit. Plus having limited time in the suit, the crew back n forth to all the different locations on the ISS to retrieve more items. operations, crews launched from the ground will be performing most of the EVA which limits the number of EVA operations per mission. EVA Fit checks are then there is very little extra time or extra resources to fix problems. Tools hav hardware have to fit, mechanical devices have to function everytime during an EVA fit checks, performed by the crew during pre-flight activities, will comb special flight/flight-like tools with the flight hardware and the planned proc fit the hardware, no interference’s exist between the tools & other hardware, together as planned and that the procedures are accurate and have all the deta perform the task. As with IVA, EVA tasks and the order they are performed cou difference between success and failure. Photo#2 - STS-88 EVA crew,Jim Newman and JerryRoss duringEVA activitieson the FirstU.S. ISS mission(ISS-2A) that berthed theUnity Element with the Zarya Elementin December of 1998. 3 Lessons Learned: Lessons learned on each mission are applied to future missions. theThissame will avo mistakes over-and-over again, helpdesign inprocess the to geta betterdata base on which to draw from when designing new fight hardware, assist problemsimilarsituations solving occur if due to error or unexpected hardware failure ISSand program allowsto the grow and gainmore experience on how to live and work in space. The followingis a seriesof lessonslearned while performing pre-fight fit checks during assembly,integration and testingfor the first two plannedU.S. ISS missions.Reference to on- orbit operations will be discussed and how the fit checksthesuccessful contributedfirst U.S. to ISS flight. These area subset justof a largerdatabase of lessonslearned while working these missions. As of thiswriting, the first U.S. ISS element,Unity, is berthed to the RussianZarya elementon-orbit, and the Z1 truss,P6 segment,Laboratory Module and MultiplePressurized LogisticModule are locatedin the Space StationProcessing Facility (SSPF) at Kennedy Space Center. All ground photo’s shown were taken in the SSPF. Static Fit Checks: As the name implies, thesefitchecks are that are staticin nature. Examples include an EVA fit check of thermal blanketsoverelectronic boxes and an IVA electrical& fluid connector mate to the Unity. Because Unity is the core element to ISS, 5 future flightsand contain will ber many Electricaland Fluidcables/connections between Unityand the new ISS elements. A process wasput in place to fitcheck all future fluid and electricaljumpers that will make these connections.This meant acceleratingmany futureIVA jumpersto allowthe fit checks to occur beforeUnity was launched. Some of thejumpers required tools that will be describedlater in thispaper, but most were a simplestatic mate to assurethe two itemswould mate on-orbit. Lesson learned, perform fit checks even for static cases. Photo #4 – IVA Fluid jumper mates proper Photo#3 – AstronautJerry Ross fitchecks to fitting but interferes with near-by thermalcover that will be placedthe Unity structure. Solution, modify end
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