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FINAL REPORT
Space Assembly, Maintenance and Servicing Study
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VOLUME V: Simulation Report OTICQÜAIITY INSPECTED 1~^^^T
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Report Number: LMSC-F104866 Vol. V Accession Number: 5185 Title: Space Assembly, Maintenance And Servicing Study Final Report, Volume V: Simulation Report Personal Author: Styczynski, T. Contract Number: F04701-86-C-0030 Report Number Assigned by Contract Monitor: STARL Corporate Author or Publisher: Lockheed Missiles & Space Company, Inc., 1111 Lockheed Way Sunnyvale, Report Prepared For: SAMS Study Program Pages: 60 Comments on Document: STARLAB RRI; Volume V of V. Descriptors, Keywords: SAMS Space Assembly Maintenance Servicing Neutral Buoyancy Simulation Robotics End Effector Telerobotics Voice Confirmation Harware Tools Operation Evaluate Electronic Documentation EVA ORU Atronaut VIMAD Tas
LMSC-F104866 Vol. V
SAMS STUDY FINAL REPORT
VOLUME V
SIMULATION REPORT
LMSC-F104866 Vol. V
INDEX TO VOLUMES
Volume I Executive Summary
Section 1.0 Introduction Section 2.0 Study Objectives Section 3.0 Study Approach and Results Section 4.0 Conclusions/Recommendations
Volume II System Analysis
Volume III Design Concepts
Volume IV Concept Development Plan
Volume V Simulation Report
Section 1.0 Section 2.0 Section 3.0 Section 4.0
Section 5.0 Section 6.0 Section 7.0 Section 8.0 Section 9.0
Section 1.0 Section 2.0 Section 3.0 Section 4.0 Section 5.0 Section 6.0
Section 1.0 Section 2.0 Section 3.0
Section 4.0
Section 5.0 Section 6.0
Section 1.0 Section 2.0 Section 3.0 Section 4.0
Introduction SAMS Study Summary Consolidated Requirements Design Reference Mission Program Scenarios Technology Requirements Logistics Cost Analysis SAMS Program Planning Conclusions/Recommendations
Introduction Design Requirements SAMS Design Concept Approaches SAMS Interface Guidelines Hardware and Tool Concepts Cost Considerations for Design Concepts
Introduction Program Summary Application Selection Methodology Candidate Selection and Prioritization Candidate Development Plan Integrated Concept Development Program
Introduction Neutral Buoyancy Simulations Robotics Simulations Conclusions and Design Recommendations
111
LMSC-F104866 Vol. V
FOREWARD
This Space Assembly, Maintenance, Servicing (SAMS) Study final report is
submitted by Lockheed Missiles and Space Company in response to SAMS Study
CDRL-027A2 per contract number F04701-86-C-0030.
This document is divided into the following five volumes:
Volume I Executive Summary
Volume II System Analysis
Volume III Design Concepts
Volume IV Concept Development Plan
Volume V Simulation Report
The Simulation Report section, Volume V, contains the following sections:
Section 1.0 Introduction
Section 2.0 Neutral Buoyancy Simulations
Section 3.0 Robotics Simulations
Section 4.0 Conclusions and Design Recommendations
Questions and/or comments concerning this document should be directed to
Thomas E. Styczynski at (408) 756-6671.
APPROVED
Carl D. Patterson
SAMS Study Program
Manager
LMSC-F104866 Vol. V
SAMS STUDY FINAL REPORT VOLUME V
TABLE OF CONTENTS
SECTION PAGE
1.0 INTRODUCTION 1-1
2.0 NEUTRAL BUOYANCY SIMULATIONS 2-1
2.1 OBJECTIVES 2-1
2.1.1 Test 1 2-1
2.1.2 Test 2 2-2
2.2 FACILITY AND TEST HARDWARE 2-4
2.2.1 Test 1 2-4
2.2.2 Test 2 2-7
2.3 SIMULATION CHRONOLOGY 2-9
2.3.1 Test 1 2-9
2.3.2 Test 2 2-13
3.0 ROBOTICS SIMULATIONS 3-1
3.1 OBJECTIVES
3.1.1 Telerobotics
3.1.2 End Effector
3.1.3 Voice Confirmation
3.2 FACILITY AND TEST HARDWARE
3.2.1 Telerobotics
3.2.2 End Effector
3.2.3 Voice Confirmation
3.3 SIMULATION CHRONOLOGY
3.3.1 Telerobotics
3.3.2 End Effector
3.3.3 Voice Confirmation
4.0 CONCLUSIONS AND DESIGN RECOMMENDATIONS 4-1
4.1 NEUTRAL BUOYANCY TESTS 4-1
4.1.1 Test 1: Orbital Refueling/Electronic 4-1
Documentation Experiment 4-4
4.1.2 Test 1: Erectable Structure Lock Assembly
Evaluation
4.1.3 Test 1: Thermal Blanket Deployment Evaluations 4-6
VII
SECTION
4.1.4
4.1.5
4.1.6
Test 1
Test 2
Test 2
4.2 ROBOTICS TESTS
LMSC-F104866
Vol. V
TABLE OF CONTENTS (Cont'd)
Environmental Enclosure Evaluation
EVA Tool Requirements Development
SAMS Designed ORU Conclusions/
Recommendations
PAGE
4-11
4-13
4-36
APPENDIX A ORS PROCEDURES
APPENDIX B HELMET MOUNTED DISPLAY TEST DATA
APPENDIX C SIMULATION MASTER VIDEO TAPE TRANSCRIPTS
vm
LIST OF ILLUSTRATIONS
LMSC-F104866 Vol. V
Figure Title Page
SECTION 2
2-1 Electronic Documentaton Test Hardware
2-2 SAMS Technology ORU
2-6
2-10
SECTION 4
4-1 AEC Single Node Workstation
4-2 Thermal Blanket Deployment Unrestrained Body Position
4-3 Blanket-to-Strut Fastener Concepts
4-4 Separating the Deployed Thermal Blankets
4-5 Environmental Enclosure Deployment Winch Evaluation
4-6 Entry Into the Environmental Enclosure
4-7 Environmental Enclosure Deployment From the Rolled
Storage Configuration
4-8 Environmental Deployment From the Folded Configuration
4-9 Data Management Unit
4-10 HST Zero Degree Connector Pliers
4-11 LEASAT Vise Grip Connector Tool
4-12 Recommended Cannon Connector Tool Jaw Configuration
4-13 Spring-loaded Shoulders in the Jaws of the 90°
Connector Pliers
4-14 HST 90° Connector Pliers
4-15 Essex EVA Ratchet Wrench
4-16 Coax Connector Hex Head Tool
4-17 Coax Connector Hex Head Tool
4-18 "D" Connector Mate and Demate Tools
4-19 Extensions for the Essex EVA Ratchet Wrench
4-20 Shrouded Screwdriver Blade Tip
4-21 Relaxed Finger Position For Gripping the Palm Wheel
4-22 "Palming" the Essex EVA Ratchet Wrench
4-5
4-7
4-10
4-12
4-14
4-15
4-16
4-17
4-18
4-24
4-25
4-26
4-28
4-29
4-31
4-32
4-33
4-35
4-37
4-38
4-39
4-40
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LMSC-F104866 Vol. V
LIST OF TABLES
Table Title Page
SECTION 2
2-1 Distribution of Test Runs, SAMS Test #1 2-11
2-2 Distribution of Test Runs, SAMS Test #2, WEEK 1 2-14
2-3 Distribution of Test Runs, SAMS Test #2, WEEK 2 2-15
2-4 SAMS Design ORU Simulation Data 2-16
SECTION 4
4-1 Thermal Blanket Deployment Timeline Data 4-8
4-2 DMU Remove/Reinstall Timeline Summary 4-20
4-3 DMU Connector Removal Timeline Data 4-21
4-4 DMU Connector Reinstallation Timeline Data 4-22
LMSC-F104866 Vol. V
ACRONYMS
\
AEC
AI Artificial Intelligence
ASE Airborn Support Equipment
B&W Black and White
CRT Cathode Ray Tube
CSTS Current and SAMS Technology Simulations
DIU Data Interface Unit
DMU Data Management Unit
DoD Department of Defense
DRM Design Reference Mission
ED Electronic Documentation
EDTG Electronic Documentation Test Group
EMU Extra Vehicular Mobility Unit
ES Equipment Section
EVA Extra Vehicular Activity
F3 Form, Fit, and Functional
FGE Fine Guidance Electronics
FSS Flight Support System
GEO Geosynchronous Earth Orbit
GFD Government Furnished Data
HMD Helmet Mounted Display
HST Hubble Space Telescope
IEO Intermediate Earth Orbit
IVA Intravehicular Activity
JSC Johnson Space Center
LEASAT Lease Craft Satellite
LCD Liquid Crystal Display
LEO Low Earth Orbit
LMSC Lockheed Missiles & Space Company, Inc.
m Meter
M&R Maintenance and Refurbishment
MAT Multiple Access Transponder
MDAC McDonnell Douglas Astronautics Company
MLI Multilayer Insulation
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LMSC-F104866 Vol. V
MMD Mean Mission Duration
MMV Manned Maneuvering Unit
MOTV Manned Orbital Transfer Vehicle
MSE Manned Spaceflight Engineer
NASA National Aeronautics and Space Administration
NB Neutral Buoyancy
NROSS Navy Remote Ocean Sensing System
NRU Non Replacable Unit
OMV Orbital Maneuvering Unit
OPS Operations
ORS Orbital Refueling System
ORU Orbital Replaceable Unit
OTS Orbital Transfer System
OTV Orbital Transfer Vehicle
PDU Power Distribution Unit
PFR Portable Foot Restraint
POC Proof of Concept
POCC Payload Operation Control Center
PRD Payload Retention Devices
PROXOPS Proximity Operations
RMS Remote Manipulator System
S/C Spacecraft
SAMS Space Assembly, Maintenance, and Servicing
SDIO Strategic Defense Initiative Office
SPTG Standard Procedure Test Group
SS Space Station
ST Space Telescope
STAS Space Transportation Architefcture Study
SV Satellite Vehicle
TPC Total Program Cost
TR Tape Recorder
TTG Training Test Group
USAF United States Air Force
UWTF Underwater Test Facility
VIMAD Voice Interactive Maintenance Aiding Device
WBS Work Breakdown Structure
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LMSC-F104866 Vol. V
1.0 Introduction
The Space Assembly, Maintenance, and Servicing (SAMS) study manned
simulation activity was designed to evaluate and demonstrate ^elected
hardware, tools, and operations concepts which promise significant
improvements over current technology in the areas of space assembly,
maintenance, and servicing. This report documents two manned neutral buoyancy
tests and a mini-series of three robotics tests performed by the Lockheed team
in support of the SAMS study contract.
The primary thrust of the first neutral buoyancy test was related to EVA
tools and operations concepts. The results apply equally to the three SAMS
missions - Assembly, Maintenance, and Servicing. The principal objective of
this test was to evaluate, under simulated EVA conditions, an electronic
documentation system designed to lead a generically EVA-trained astronaut
through a complex EVA servicing task with which he had no previous training.
Two separate electronic information management systems were evaluated. The
system used for the primary data runs, developed by Lockheed, was based on
video tape. The second system, known as the Voice Interactive Maintenance
Aiding Device (VIMAD), was developed by Honeywell. It was based on a laser
disk. Both systems provided video and audio signals to a Helmet Mounted
Display (HMD) developed by Carnegie-Melon University. The known EVA task
selected as a basis for evaluating the electronic information management
systems was the Orbital Refueling System (ORS) hydrazine transfer experiment
flown on STS-41G. This test marked the first known time that a HMD and an
associated electronic information management system have been used on a space
suit in an actual neutral buoyancy test. This test produced a comparison of
task performance by test subjects familar with the task and performing from
memory, with performance by equally experienced subjects unfamiliar with the
task and relying on instructions provided by the electronic documentation
system.
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In addition to the primary test, three space assembly technology
experiments were conducted on a time-available basis. Hardware items for
these evaluations were provided by ILC-Dover, ILC-Houston, and the Able
Engineering Company.
This test was conducted in the McDonnell-Douglas Underwater Test Facility
(UWTF) in Huntington Beach, CA, during 4 days of suited operations in early
February 1987.
The thrust of the second neutral buoyancy test was also related to EVA
tools. The results are primarily applicable to maintenance aspects of SAMS
missions. The first objective of this test was to evaluate EVA changeout of 5
current technology ORU's, using a new set of NASA developed EVA hand tools«
The second major objective was to evaluate EVA changeout of a new modular ORU
concept which is also robot-compatible. The modular ORU was evaluated in two
sizes; the largest was a trapezoidally shaped box whose major dimensions were
54.0" x 38.1" x 18.4", of mass equivalent to 1100 lbs.
A second generation version of the Orbital Refueling System electronic
documentation system procedures tape used during the first neutral buoyancy
test was also evaluated on a time-available basis during this experiment.
The second neutral buoyancy test was conducted in the McDonnell-Douglas
UWTF during 10 days ff£ suited testing beginning in mid-March, 1987.
All hardware elements for both neutral buoyancy test series were
thoroughly evaluated by at least one of two experienced Lockheed EVA test
crewmembers. A number of USAF MSE's also participated in each test series.
The objective of the robotics tests was to evaluate robot performance in a
series of human-robot interaction tasks which are representative of functions
inherent in most servicing operations. Tests performed in this series
included robotic retrieval of a specific tool from a tool board and holding it
at a prescribed position; replacing a tool in a tool board after being handed
the tool by an astronaut, sensing an astronauts hand position and handing a
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specific tool directly to the hand location, and working in parallel with an
astronaut to remove and replace an ORU from a rack. For this latter task, the
robot sensed the force inputs of the astronaut and duplicated them on a
parallel handhold.
The rototics tests were performed in the Robotics Institute at
Carnegie-Melon University, Pittsburgh, PA.
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2.0 NEUTRAL BUOYANCY SIMULATIONS
2.1 OBJECTIVES
2.1.1 Test 1:
Test 1 was divided into two experiments. The prime experiment was the
evaluation of EVA application of electronic data management systems. The
secondary experiment was a three part evaluation of EVA assembly technology.
The primary objective of the first neutral buoyancy experiment was to evaluate
an electronic data management system and associated crewmember display as a
means of enhancing EVA crewmember performance and/or reducing EVA crewmember
training time. Specific sub-element objectives were:
o Evaluate one or more concepts for displaying electronic information to a
suited astronaut,
o Demonstrate simulated voice control for management and retrieval of
system information,
o Evaluate the potential for either improving EVA crewmember performance
or markedly reducing EVA crewmember training time,
o Evaluate impact to IVA and EVA crew communications,
o Establish timeline and procedural data base for evaluating future manned
space flight engineer neutral buoyancy simulations.
The objective of the first assembly technology experiment was to evaluate a
new lock assembly concept for attaching struts to nodes during the on-orbit
buildup of an erectable structure. Specific sub-element objectives were:
o Evaluate glove/strut interface characteristics.
o Evaluate strut installation and release operations.
The objective of the second assembly technology experiment was to evaluate
techniques for installing insulation blankets on large space structures.
Specific sub-element objectives were:
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LMSC-F104866 Vol. V
o Evaluate an unrestrained two person manual blanket deployment technique,
o Evaluate 3 blanket-to-truss attachment concepts.
The objective of the third assembly technology experiment was to evaluate the
deployment and operation of a one niece environmental enclosure.
Specific sub-element objectives were:
o Evaluate a two person manual deployment concept.
o Evaluate a manually operated winch as an aid to deploying the enclosure
and restraining it until the attachments to adjacent strut structure
were complete,
o Evaluate crew operations required to open and close the enclosure
entrance door,
o Evaluate crew entry/exit from the enclosure,
o Evaluate crew translation along one internal edge of the enclosure.
2.1.2 Test 2:
There were two objectives of the second neutral buoyancy test series. The
first was to perform detailed evaluations of 5 representative current
technology ORU's, using current technology EVA handtools, to provide a basis
for development of EVA handtool requirements for the early SAMS epoch. The
emphasis in this investigation was on "generic task realism", i.e., the
objective was to ensure that the task used for each specific tool evaluation
was realistic. For this reason, dimensionally accurate mockups were
fabricated of ORU's from an actual spacecraft program, with attention to
connector types, spacing, orientation and pin loading. These ORU mockups were
generically placed in a raockup of two spacecraft equipment bays. The
objective was to represent typical mounting situations which are encountered
in actual spacecraft, rather than to look at access limitations which are
peculiar to a particular spacecraft.
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LMSC-F104866 Vol. V
The second major objective of the second neutral buoyancy test series was to
perform a preliminary crew interface evaluation of a new ORU mounting concept,
known as the "sword and scabbard", developed by Lockheed for the SAMS Study.
The concept integrates the installation alignment aids, the mechanical
mounting interfaces, and the electrical interfaces so that the crewmember is
required to manually position and align the ORU to start into the alignment
guide, push the ORU down the guide to the fully installed position, and then
use a tool on a single mechanical connector to secure the ORU to the
spacecraft.
Specific sub-objectives of this task included:
(1) Determining the acceptable range for foot restraint height with
respect to the ORU mounting interface location, and the preferred foot
restraint height, for the following test conditions:
o Large ORU; sword and scabbard centrally mounted on one side.
o Small ORU; sword and scabbard centrally mounted on one side.
o Small ORU; sword and scabbard centrally mounted on top of the ORU.
o Small ORU; sword and scabbard centrally mounted on the bottom of the ORU.
(2) Determining handhold requirements on the ORU to facilitate manual
handling and positioning for installation. Of particular interest was
examination of any requirements for handholds mounted on ORU surfaces other
than the front face.
(3) Evaluating the operation of the blade and scabbard concept as
represented by the first generation mockup, with respect to pre-installation
ORU positioning requirements, entry ramp angles, blade and scabbard clearances
and alignment pin geometry.
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2.2 FACILITY AND TEST HARDWARE
The facility for both neutral buoyancy tests was the McDonnell-Douglas
Underwater Test Facility (UWTF) at Huntington Beach, California. The UWTF is
a 70' diameter by 35' deep, covered, in-gound neutral buoyancy facility with
extensive audiovisual monitoring and recording capabilities, and provisions
for simultaneous operations by two space shuttle extravehicular mobility units
(EMU's).
2.2.1 Test 1:
The test-unique hardware equipment items, listed by supplier developer, were
the following:
NASA JSC:
o One (1) STS-41G Orbital Refueling System (ORS) neutral buoyancy crew
trainer, including the following tools:
- ball valve housing
- cap retainer
- dust cap removal
- multipurpose tool
- nut retainer assemby
- retrieval tool
- seal verification tool
- spanner
- wire clippers
LMSC:
o One (1) multipurpose test stand
o Two (2) multipurpose test stand extensions
o One (1) ORS to test stand interface adapter
o One (1) single node test stand and attached foot restraint
o One (1) multipurpose test stand to 5m bay cruciform interface adapter
o Four (4) test stand nodes
o Two (2) 5m bays of erectable truss
o One (1) ORS procedures video tape 2-4
LMSC-F104866 Vol. V
CMU:
o One (1) Black and White (B&W) Helmet Mounted Display system
Honeywell:
o One (1) VIMAD system
o One (1) ORS procedures laser disc
ILC:
o One (1) multilayer insulation (MLI) blanket dispenser
o Five (5) MLI blanket mockups (neutrally buoyant mesh)
o Two (2) wrist tethers
o One (1) 5m environmental enclosure (neutrally buoyant mesh)
o Two (2) EVA winches
ABLE ENGINEERING COMPANY (AEC)
o One (1) AEC erectable structure node
o Eight (8) AEC neutrally buoyant short struts and lock assemblies
The Electronic Documentation Test Hardware (Fig. 2-1) used during the LMSC
simulations utilized a Helmet Mounted Display (HMD) that consisted a small
CRT, a mirror held at the appropriate angle and the surrounding structure and
shroud. Data was supplied to the HMD by a Video Cassette Recorder with freeze
frame capability via a 100' waterproof line.
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•-3 3 "3
i
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2.2.2 Test 2:
The test-unique hardware equipment items listed by supplier or developer, were
the following:
LMSC:
o A representative spacecraft equipment section including 3 bays; two
equipped with functional doors and latches,
o Five (5) common adapter plates allowing mounting of ORU's internally in
the bays, or on the bay doors,
o One (1) LMSC multipurpose support stand and 2 foot restraint adapters,
o Two (2) stand extensions
o Five (5) representative current technology ORU's.
o Two (2) SAMS technology ORU's with multiple crew interface mounting
provisions.
USAF:
o Two (2) Portable EVA foot restraints.
NASA JSC:
o EVA handtools required for the current technology ORU changeouts,
including:
- Hex Coax Connector Tool
- Shrouded Flex Screwdriver
- "D" Connector Demate Tool
- "D" Connector Mate Tool
- 5/16" Rigid Hex Capture Tool W/10.3" Extension
- Adjustable Door Stay .
- 3/8" Drive McTether Ratchet
- Equipment Tether, 34"
- Ratchet McCaddy
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NASA JSC (CONTINUED)
- Standard McCaddy
- Waist Tether
- Wrist Tether
- Mini-Work Station
- Torque-Set Tip Tool #10 Assembly
- 90 deg Circular Connector Tool
- Trash Bag, Large W/Lips
- Electrical Connector Pin Straightener
- Trash Bag, Small
- 0 deg Circular Connector Tool
- Rigid Hex Capture Tool W/10.3" Extenion
- 5/16" Wobble Hex Capture Tool 10.3" Extension
Leasat Connector Tool
NASA MSFC
o EVA handtools required for the current technology ORU changeouts,
including:
7/16" Sock. 6" Extension
7/16" Sock. 12" Extension
9.0 Ft-lb Torque Limiter
o Portable foot restraint
o Portable ORU Handle, Small
o Portable ORU Handle, Large
The LMSC SAMS ORU was designed to utilize a single interface attachment
mechanism known as the "sword and scabbard". The intent of such a mechanism
is to provide the-ORU with the required structural, electrical and fluid
interfaces with one attachment, eliminating a great deal of the EVA crewmember
workload and providing an interface system workable by remote servicing
systems. The "sword" is a blade mounted to the ORU tapered at the end
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LMSC-F104866 Vol. V
designed to interface with the "scabbard", a channel mounted on the
spacecraft. Electrical and/or fluid interfaces are on two facing plates
integral to the system.
The ORU itself, as depicted in Fig. 2-2 was designed to simulate two sizes of
flight ORUs, one large enough to fill an entire bay of the CSTS hardware and a
smaller version, attained by the removal of two sections. The attachment
system was designed to be tested in three different positions, mounted on the
side of the bay, the top of the bay, and the bottom of the bay. The full size
ORU could only be operated with the interface mounted in the side position.
The ORU was also designed with two sets of handholds included in the
experiment to determine their usefulness. One pair of handholds was mounted
to the outer face of unit (see Fig. 2-2) and the other pair was mounted in a
recessed position on the left side of the ORU. To aid visual cues, the
"sword" was painted red and the "scabbard" was painted yellow versus the basic
grey of the main structure and white of the ORU itself.
During simulation runs, the Portable Foot Restraint (PFR) was mounted to the
left side of the ORU bay to facilitate the removal and installation of the
ORU. During the simulation of the bottom mounted interface, however, the PFR
was mounted directly below the bay.
2.3 SIMULATION CHRONOLOGY AND RESULTS
The distribution of daily test activity among the experiments is listed in
Table 2-3. The remainder of this section summaries each day's test activity.
2.3.1 Test 1:
Day 1: Setup and checkout of the EMU's and umbilicals occupied the full
day. No suited test runs were attempted.
The integration and checkout of the electronic documentation system equipment
the Honeywell-supplied Voice Interactive Maintenance Aiding Device (VIMAD) and
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3 az O
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1—1
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CM I CM
60
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LMSC-F104866 Vol. V
TUES. WED. THURS. FRI. EXPERIMENT 3 FEBRUARY 4 FEBRUARY 5 FEBRUARY 6 FEBRUARY
AM PM AM PM AM PM AM PM
ELECTRONIC LMSC LMSC USAF USAF USAF USAF USAF
DOCUMENTATION USAF USAF USAF USAF
AEC LOGIC LMSC
ASSEMBLY
THERMAL LMSC USAF
COVERS
ENVIRONMENTAL LMSC
ENCLOSURE
Table 2-1 Distrubution of Runs For the First Neutral Buoyancy
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associated laser disc-based ORS procedures, the Carnegie-Mellon University
(CMU) Helmet Mounted Display (HMD), and the LMSC-produced ORS procudures video
tape played on UWTF equipment revealed synchronization instabilities resulting
from the long signal line lengths and multiple connections. The result was
substantial signal degradation as viewed both on the HMD and on the control
room monitors. In addition, apparant HMD clarity was further distorted by
numerous scratches present in the helmet which were amplified by glare from
stray light.
Day 2: EMU operations were scheduled in parallel to initiate assembly
technology experiment operations with one of the LMSC test crewmembers while
the other continued to work with the HMD and the associated electronic system.
By the end of Day 2, based on two suited ORS exploratory dives, an electronic
system was selected for the ORS runs, consisting of the CMU-developed single
mirror, 4" B&W Sony CRT-based HMD and the LMSC-developed ORS procedures video
tape played by a UWTF control room recorder and special effects generator.
For the MSE data runs the system was operated by one of the Lockheed EVA test
crewmembers simulating voice control. The options evaluated in selecting this
test configuration included various combinations of CRT and-Liquid Crystal
Display (LCD) based HMD's, various HMD mirror combinations (half silvered, 60%
silvered, full silvered, single and two mirror combinations), and two
interpretations of how to present the ORS procedures to the subject (one
produced by Honeywell on laser disk, the other by LMSC on video tape). In
addition, the AEC erectable structure lock assembly evaluation and 4 of the 5
environmental enclosure evaluation objectives were completed.
Day 3: The thermal blanket installation test was completed by both LMSC
crewmembers working together.
The first experiment test run (the ORS procedure by a trained subject) was
performed by a USAF subject. Two USAF subjects then performed the thermal
blanket deployment test, and the second USAF subject then completed the second
primary experiment run (the ORS procedure performed by an ;: rained subject
using the electronic documentation system).
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Day 4: Four experiment runs were conducted using USAF subjects. The
final run was truncated slightly due to slow performance by the subject and
lack of time at day's end.
Day 5: Three experiment runs were performed, including one "double run"
by a USAF electronic subject to permit a back-to-back comparison of both the
Lockheed and the Honeywell versions of the ORS instructional procedures.
2.3.2 Test 2:
The second neutral buoyancy test series included 10 days of suited
operations. The distribution of daily test activity is summarized in
Tables 2-2 and 2-3.
During the first week of simulations, the SAMS designed ÖRU remained in the
large ORU configuration and was cycled by several test subjects. The results
of these runs are summarized in the overall conclusions and recommendations
section. The tests during this period began with the loosening of the attach
bolt with the proper size socket and ratchet. The ORU was then cycled in and
out of the interface mechanism several times by each subject while their
comments and suggestions were recorded. All subjects utilized essentially the
same foot restraint position all week.
Monday and Tuesday of the second week of simulations a series of detailed
tests with the ORU system were performed. Monday, four foot restraint
positions were tried, and each removal and insertion cycle were timed, all
with the large configuration ORU. Each test was run four times, each with a
different viewing angle from the swim camera. Tuesday, the small
configuration ORU was used with the same foot restraint positions as Monday's
tests. The two other interface positions were also tried, one at the bottom
of the CSTS bay and one at the top of the bay, both with the small ORU.
The data from these runs is presented in Table 2-4. Foot restraint position
is defined by the vertical distance of the subject's eyes from the attach bolt
of the ORU interface system. This measurement determines sighting angles for
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LMSC-F104866 Vol. V
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2-14
LMSC-F104866 Vol. V
Table 2-3 DISTRIBUTION RUNS, SAMS TEST #2, WEEK 2 e 3 M
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2-15
LMSC-F104866 Vol. V
Table 2-4 SAMS DESIGN ORU SIMULATION DATA
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2-16
LMSC-F104866 Vol. V
visual cues and the angle at which the subject's arms are used during removal
and installation of the ORU. The times given are averages of the several runs
at each foot restraint position.
The simulations conducted during the remainder of the week were to those of
week one in that each test subject cycled the system and their comments and
suggestions were recorded.
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(This page intentionally left blank)
2-18
LMSC-F104866 Vol. V, Sec. 3.0
3.0 ROBOTICS SIMULATIONS
3.1 OBJECTIVES
3.1.1 Telerobotics
3.1.2 End Effector
3.1.3 Voice Confirmation
3.2 FACILITY AND TEST HARDWARE
3.2.1 Telerobotics
3.2.2 End Effector
3.2.3 Voice Confirmation
3.3 SIMULATION CHRONOLOGY
3.3.1 Telerobotics
3.3.2 End Effector
3.3.3 Voice Confirmation
(To be supplied)
3-1
LMSC-F104866 Vol. V, Sec. 3.0
(This page intentionally left blank)
3-2
LMSC-F104866 Vol. V
4.0 OBSERVATIONS AND CONCLUSIONS
This section includes summary observations on the results of each experiment
performed by the Lockheed team in support of the SAMS study contract (neutral
buoyancy as well as robotic) and specific conclusions and/or design
recommendations resulting from each test.
4.1 NEUTRAL BUOYANCY TESTS
The following are the results of the two neutral buoyancy test series, which
included a total of 14 days of dual suit operations in the McDonnell-Douglas
UWTF.
4.1.1 Test 1: Orbital Refueling System/Electronic Documentation Experiment
The ob iective of this experiment was to investigate the feasibility of
providing task procedures information to an EVA crewmember, using a Helmet
Mounted Display (HMD) driven by an electronic documentation svstemf and to
develop a set of formatting recommendations for the development of future task
procedures to be utilized with an HMD. Observations relative to HMD hardware
systems were collected secondarily and are presented at the end of this
section.
This experiment resulted in a significant industry milestone by accomplishing
the first neutral buoyancy evaluation of a Helmet Mounted Display driven by an
electronic documentation system. Nine test runs were completed with USAF
subjects. The tests clearly indicate the potential that electronic
documentation systems have for enhancing EVA crewmember performance, and also
provided much insight into how procedures information should be formatted to
optimize visability by the crewmember.
Specific recommendations related to the presentation of task information to
the EVA crewmember are as follows:
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LMSC-F104866 Vol. V
(1) The presentation should be designed to illustrate several related
steps of a procedure on verbal command from a crewmember, and then to
go automatically into a hold mode, while the crewmember performs
those steps. The crewmember should dedicate his attention to the
display while it is active, and not begin work until the display goes
into the hold mode, to avoid missing details of the presentation.
(2) The task to be performed should be illustrated by clear, high
contrast video illustrating the steps-^-to be performed. It is
desirable to use high fidelity hardware, wi£n extreme closeups to
illustrate details. Care must be taken to indicate to the crewmember
the location of the object of the closeup.
(3) The steps to be performed should be described aurally as the video is
presented.
(4) At the conclusion of each short series of steps, the display should
go into a "freeze frame1' mode, illustrating the configuration to be
reached at the conclusion of the series of steps. The steps required
should be sequentially summarized in cryptic text and display the
same Trane; the display of the text should not overlay or otherwise
occlude the video. The text should include all relevant information
on turn counts, direction of rotations, settings, pressures, etc.
For example, if the objective of a task is to obtain a specific tool,
the freeze frame should show the tool, presented so that all
significant features are visible, with the tether configuration(s)
clearly shown, and tool setting(s) shown for the upcoming task.
(5) The presentation should be voice-controlled. When a task is
completed, the presentation of the next task should be immediately
available on verbal command.
(6) The voice control capability should include commands for
instantaneous hold, reverse, slow forward, access to detailed "help
instructions, selection of alternate procedures at decision points,
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LMSC-F104866 Vol. V
etc.
(7) Caution and warning information relevant to any steps to be performed
in a given task sequence should be clearly indicated prior to the
crewmember beginning work on that sequence.
(8) A brief statement of the objective of the procedure, the total number
of steps in the procedures, and the nominal task performance time
should be included at the beginning of the procedure.
(9) The task sequence number (i.e., a sequential number assigned to each
successive set of steps grouped for presentation) and the total
number of task sequences in the end-to-end procedure, should be
displayed at the beginning of each task sequence.
Observations relevant to the design and functioning of the HMD system itself
are as follows:
(1) HMD protrusion above and in front of the helmet must be strictly
minimized.
(2) The binocular display used for this experiment, (centered, and high
in the field of view) was judged comfortable and acceptable by all
subjects. The display and any associated shroud must not interface
with crewmember vision up and to either side, and should be
positioned to permit straight ahead (eyes level) viewing of the
worksite in front of the crewmember.
(3) It must be recognized that the use of an HMD in an EVA situation is
markedly different from use for a piloting application; accordingly,
although several partially silvered mirrors were examined in the
initial hardware evaluation runs in the water, to permit a degree of
visibility through the display, it was judged more desirable to use a
full-silvered, shrouded mirror for this application, for two reasons:
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LMSC-F104866 Vol. V
(a) Attention to fine details, maskings, etc. is often crucial to
error-free task performance. These details may be masked by the
contrasts or action in the field of view beyond the display.
(b) Since the crewmember is not moving or otherwise interacting with
the workstation during the presentation of the material on the
HMD, it is not important to see what is happening behind the
display. The majority of the_volume normally visible forward
and above the helmet can be monitored by looking around the HMD
display, providing that the display is kept reasonably narrow
and not allowed to restrict more of the width of the field of
view than is occupied by the difglay fitself•
(4) The display screen should be designed to be readily^folded or x
retracted out of the way when not in use, or in the event that the
display does occlude vision in a particujLar situation.
(5) The unit must be designed to withstand minor bumps and impacts
without damage or loss of mirror alignment.
(6) The display should not be overly sensitive to head height or"lateral
position in the helmet.
4.1.2 Test 2: Erectable Structure Lock Assembly Evaluation
This test marked the first neutral buoyancy evaluation of the Able Engineering
Company (AEC) erectable lock assembly. The single node work station used in
the evaluation is shown in Fig. 4-1. All eight examples of the lock assembly
were unfortunately plagued by inadvertant, premature triggering of the preload
device during strut installation onto the node. This characteristic, which
was not evident in the 1-G checkout runs, limited the ability to get useful
installation timeline data, but did not interfere significantly with the
evaluation of the flight crew interface aspects of the design. The following
observations and design recommendations resulted from the test:
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LMSC-F104866 Vol. V
Fig. 4-1 AEC Single Node Workstation
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LMSC-F104866 Vol. V
(1) The linear action required to lock the strut onto the node is much
less fatiguing than the rotary motion required to lock many current
lock assembly concepts.
(2) The lock assembly design required that the strut by fairly precisely
aligned prior to insertion into the slot on the node. The crew
workload and task performance time could be reduced by modifying the
lock assembly to permit 4-5° of strut misalignment.
(3) The lock assembly design required that the strut be rotationally
positioned precisely to one of six possible orientations to allow the
nex nut on the strut to drop into the slot on the node. This
rotational positioning is normally accomplished by a wrist motion,
and is somewhat fatiguing and time-consuming. It is desirable that
the strut insertion be independent of angular orientation.
(4) The triggering mechanism design should incorporate sufficient
friction so that the strut can be handled, with the hand gripping the
sleeve which triggers the locking action, without prematurely
activating the lock. No separate lock should be required to prevent
premature activation.
(5) A technique must be provided to the crewmember to reset a lock if
prematurely triggered, or if it becomes necessary to remove and
replace a strut.
4.1.3 Test 1: Thermal Blanket Deployment Evaluations
A objective of this test was to determine the feasibility of manual deployment
of large thermal blankets (or other soft goods) and manual attachment to a
base support structure, by two EVA personnel working without foot restraints
(see Fig. 4-2), and to determine the approximate task performance times. The
results of this test, as conducted the first time by two Lockheed EVA test
crewmembers, are summarized in Table 4.1.
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Fig. 4-2 Thermal Blanket Deployment Unrestrained Body Position
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LMSC-F104866 Vol. V
TABLE 4-1 THERMAL BLANKET DEPLOYMENT TIMELINE DATA
TIME (MIN:SEC)
Prepare Dispenser 0:35
Attach Wrist Tethers 0:24
Blanket Reaches First Node 0:39
Blanket Reaches First Node 0:54
Blanket Reaches Third Node 0:58
First 2 Far End Straps 0:45
Attached and Cinched
Wrist Tethers Released 0:10
Remaining 3 Far End Straps 1:10
Attached and Cinched
Fastex Panel Side Straps
Attached and Cinched
EV-1 (2:30)*
EV-2 0:3:40
Waterbury Clip Panel Side
Straps Attached and Cinched
EV-1 (2:50)*
EV-2 0:4:15
Velcro Strap Panel Side
Straps Attached
EV-1 (3:28)*
EV-2 0:3:40
Third Panel Separated 0:1:10
From Dispenser
Third Panel Trailing Edge 4:22
Attached To Strut
*TIME NOT INCLUDED IN TOTAL
EV-1 AND EV-2 WORKING SIMULTANEOUSLY.
TOTAL TIME IS REPRESENTATIVE OF THE
LONGEST TIME TO COMPLETE TASK. 4"8
Total Time To Install 3 Panels 22 min 42 sec
LMSC-F104866 Vol. V
A second objective was to critique the first generation tnockup hardware used
for this test and formulate a set of design guidelines for use in the Space
Based Radar design effort (DRM 4). The following observations and design
recommendations resulted from this test:
(1) Manual deployment of large (5 meter wide), flexible panels by two
crewmembers working without foot restraints is feasible.
Significantly wider panels appear feasible. Three sequentially
joined 5 meter long panels were deployed during the test. The
results indicate that much longer panels should be deployable under
actual EVA conditions. It should be noted, however, that since this
concept relies on extensive use of the hands and arms, good
hand/glove and glove/strut fit is important.
(2) The roller concept for dispensing the blanket panels is a good
blanket management approach.
(3) A slight retraction force incorporated in the dispenser roller
appears useful in maintaining blanket position next to the base
structure prior to attachment of the deployed blanket. The amount of
friction in the dispenser, however, should be kept to minimum. The
two test crewmembers estimated that a combined pulling force of at
least 40 lbs. was required to deploy the blankets in the test, and it
remained fairly constant over the entire deployment cycle. This
force resulted from inadvertent contact of the velcro sufaces in the
closeout panels along the edge of each blanket panel, and was
unacceptably high for sustained deployment operations. It was
estimated that a combined force of 1 pound would be a desirable goal.
(4) A spreader bar was incorporated in the leading edge of the first
panel to maintain a streamlined shape in the water. This may also be
necessary in the vacuum environment so that the leading edge shape
can be maintained without requiring the crewmember to maintain
tension across the leading edge. (Tension applied in this way would
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INTERNAL FRAME ATTACHMENT (VELCRO BUCKLE)
CORNER GEOMETRIC CONFIGURATION
LMSC-F104866 Vol. V
(Other Concepts To Be Supplied)
Fig. 4-3 Blanket To Strut Fastener Concepts
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LMSC-F104866 Vol. V
tend to cause crewmember rotation around the strut, which would have to be
resisted by the hand grip on the strut.)
(5) All three blanket-to-strut fastener concepts evaluated were operable,
however, the Fastex concept was much preferred over the modified
Waterbury clip or the Velcro strap. The three concepts are
illustrated in Fig. 4-3.
(6) No significant problems were encountered in separating the deployed
panel(s) from the succeeding panel still in the dispenser (Fig.
4-4). The Velcro panel-to-panel attachment concept was the sole
concept evaluated, however it appeared that the Fastex concept also
would have been satisfactory. It is perferable to have a concept
which releases easily with one hand, while the other hand is used to
grip the strut adjacent to the separation interface, to maintain body
position. The two crewmembers started at the two corners of the
panel and worked their way to the middle.
(7) Panel-to-panel closeouts around a 90° corner were also evaluated
and found to be feasible, again working without foot restraints. The
two crewmembers started at mid-panel, working together to stretch one
closeout panel around the strut, and then pull the second closeout
panel across the first, and attch it to the first with Velcro. Three
observations were:
(a) It would be desirable to develop a panel design concept which
does not require separate closeout panels.
(b) If closeout panels are employed, a stowage concept should be
devised to keep the panels folded back and lightly secured to
the panel during panel deployment, so that they remain out of
the way during panel attachment to the struts.
(c) Some type of mobility loops are needed which are accessible to
the crewmember after panel closeouts are installed to permit
translation along the outside of a structure covered with
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LMSC-F104866 Vol. V
Fig. 4-4 Separating The Deployed Thermal Blankets
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LMSC-F104866 Vol. V
panels. The loops should be co-located with the straps which attach the
panels to the truss structure to give a degree of rigidity to the loops.
4.1.4 Test 1: Environmental Enclosure Evaluation
Two predeployment packaging concepts are possible for the environmental
enclosure - folded, and rolled. The folded approach was used for this test.
It was apparent during the pretest SCUBA checkout of this hardware that
deployment in the EMU's would be unnecessarily tiring and time consuming,
without additional straps and fasteners aid in regulation deployment.
Therefore, suited activities in support of the environmental enclosure were
limited to evaluation of the deployment winch operations (Fig. 4-5), operation
of the structural attachment concepts (a strap and Fastex fastener concept),
operation of the crew entry door (opening, closing, and locking), crew entry
and exit through the crew entry door (Fig. 4-6), and crew mobility inside the
deployed enclosure. No major problems were encountered. It was noted that a
bi-fold entry and exit door would have been easier for a single EVA crewmember
to operate than the large (54" square) single fold door evaluated during this
test.
Subsequent to the test, concepts for suited deployment of a 5 m cubical baggie
have been developed for both the rolled and the folded launch configurations.
It is believed that the rolled approach is easier and could be accomplished
with the hardware as tested. (See Fig. 4-7). The folded approach also
appears feasible, however, it requires the addition of more straps and
fasteners to permit the crewmember to divide the enclosure deployment into
phases, so each newly deployed portion can be fastened to the truss structure
before the next portion is released. The phased approach to enclosure
deployment from the folded configuration is illustrated in Fig. 4-8.
4.1.5 Test 2: EVA Tool Requirements Development
The emphasis of the second neutral buoyancy test series was to develop
functional requirements for EVA hand tools to support electrical and
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LMSC-F104866 Vol. V
*5.
Fig. 4-5 Environmental Enclosure Deployment - Winch Evaluation
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LMSC-F104866 Vol. V
-«BSfc.
■4
Fig. 4-6 Entry Into The Environmental Enclosure
4-15
LMSC-F104866 Vol. V
(To Be Supplied)
Fig. 4-7 Environmental Enclosure Deployment From Rolled Storage Configuration
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LMSC-F104866 Vol. V
(To Be Supplied)
Fig. 4-8 Environmental Enclosure Deployment From Folded Configuration
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LMSC-F104866 Vol. V
(To Be Supplied)
Fig. 4-9 Data Management Unit
4-18
LMSC-F104866 Vol. V
mechanical connector mate/demate operations. As part of this objective, the
most complex ORU exchange task utilizing the Data Management Unit as the ORU,
Fig. 4-9, was performed end-to-end by the senior Lockheed EVA test
crewmember. The purpose of this test was to obtain a total remove/reinstall
timeline for a complex current technology spacecraft equipment item,
identifying the distribution of Jsame between the various components of the
task, and identifying task elements leading to excessive fatigure. Special
emphasis was placed on identifying fatigue-inducing aspects of tool design.
The results of this test are summarized in Table 4-2. A detailed breakdown of
the removal data is presented in Table-J>r3, and a detailed breakdown of the
«installation data is presented in Table 4-4.
It should be emphasized that the individual removal and «installation times
are actual working times, beginning with the appropriate tool or connector
pigtail in hand, and the task elements visually located. Extreme care was
taken to avoid bending pins or stressing wires through inadvertent contact
with tool's--ör hands; nomockup damage was sustained' luriög thrs "&LMM.*
Hand and finger fatigue was a significant factor in this test, even though the
actual working time was distributed over three separate dives on two
successive days. Test crewmember comments indicated that, givjsn the test
configuration and tools^as evaluated for this test, the m^sured task
performance times Jfjrou-ld be doubled to allow a minimum acceptable degree of
hand and finger recovery between tasks, fin addition, deSrelopmeh^of a
projected orbital timeline for;, this task would need to i»cludej|ime to prepare
the worksite (open the access door, install door stiy, install and position
the foot restraint, adjust the foot restraint periodically during the task,
set up and restore tools, etc., and then reverse these steps to close out the
task). In summary, it appears that this task, if performed end-to-iffä Tpr
on-orbit, would require 6 »7 hours of EVA time*
Specific observations and recommendations from-tnis:test which relate to
selected tools from the recommended generic tool set for early SAMS missions
are the following:
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LMSC-F104866 Vol. V
TABLE 4-2 DMU REMOVAL/REINSTALLATION TIMELINE SUMMARY
ITEM
COUNT
Connector Removal
Forward Cannon (12)
Forward Coax (7)
Aft Cannon (12)
Aft Coax (7)
TIME
(MIN:SEC)
2:05
8:01
2:24
13:15
Bolt Removal (20 bolts) 15:06
ORU Removal :30
ORU Repositioning
(includes alignment guide installation)
:45
Bolt Installation (20) 38:09
Connector Reinstallation
Forward Coax (7)
Forward Cannon (12)
Aft Coax (7)
Aft Cannon (12)
16:00
16:05
13:10
34:41
Total Working Time: 160 min 11 sec
NOTE: Total working time is on-station time spent actually installing or
removing bolts or connectors. Workstation preparation, foot restraint
ingress/egress, tool set up, tool retrieval for each task, rest
periods, workstation closeout not included.
4-20
TABLE 4-3 DMU CONNECTOR REMOVAL TIMELINE DATA
LMSC-F104866 Vol. V
CONNECTOR CONNECTOR TOOL USAGE TIME NOTES
# TYPE HAND 0° PLIERS LEASAT MIN: SEC
J20 Cannon X 19 J12 ti X 14 J14 ii X 13 J3 ii X 14 J8 ii X 14 J6 II X 11 J4 ti X 12 J24 ii X 10 J10 ii X 10 J13 II X Conn, missing J7 II X :16 J2 II X :11 J26 Coax X X 1:48
J30 ti X X 1:12 J28 ii X 2:17 J32 it X 1:21 J34 ii X 2:50
J36 it Conn, missing J38 it Conn, missing
J5 Cannon X 12 Jl II X 11 J16 II X :07 J18 it X .12 J13 ii X :08 Jll II X :09 J15 ti X :06 J9 II X :08 J22 it X :10 J19 it X :12 J21 II X :07 J23 II X :23 J25 Coax X X 1 :00 J27 II X X :58 J29 II X :56 J31 it Conn, missing J33 it
X 2:02 J35 II X 1:43
J37 II X 1 :22
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LMSC-F104866 Vol. V
TABLE 4-4 DMU CONNECTOR REINSTALLATION TIMELINE DATA
CONNECTOR CONNECTOR TOOL USAGE TIME NOTES
# TYPE HAND 0° PLIERS LEASAT MIN:SEC
J38 Coax Conn, missing J36 ii
Conn, missing J34 ii X X 1: 36 J32 ti
X X 1: 48 J30 ii X X 2: 07 J28 ii
X X 1: 07 J26 ii X X 1: 53 J2 Cannon X 41 J4 ii X X 10 21 J6 ii
X 1 00 J8 ii X 4 36 J3 II
X 9 10 J7 II
X 32 J14 II
X 59 J12 II
X 1 08 J10 II
X 50 J20 ti
X 2 20 J24 ii
X X 11 J17 II X Conn, missing J37 Coax X .2:25 . J35 II X 2:09 J33 v- II
X 3:39 J31 II X Conn, missing J29 II
X 1:21 J27 II X 2:34 J25 II
X 1:39 J5 Cannon X 5:22 J19 II Data missing J21 II Data missing Jl II
X :14 J16 II X X 1 :59 J18 II
X X :35 J13 II X X :55 Jll II
X 1 :04 J15 II
X :46 J9 II
X :19 J22 II
X 1 :05 J23 II
Data missing
4-22
LMSC-F104866 Vol. V
4.1.5.1 In-line Connector Pliers. This type of tool is necessary to install
and remove closely spaced cannon-type electrical connectors (when spacing
precludes gloved-hand access), when the access envelope is in line with the
connector long axis. In cases where gloved hand access is marginal, use of a
tool of this type will reduce the potential for inadvertant damage to adjacent
wires, and will also eliminate the potential for damage to the glove from
exposed thread sections on adjacent "open" connectors.
Two separate tools were evaluated for this application - the HST Zero-Degree
Connector Pliers (Fig. 4-10) and the LEASAT vise grips (Fig. 4-11).
Functionally, the major diffrence was that the zero-degree pliers required
constant hand pressure to maintain the grip on the connector, while the vise
grips could be locked on the connector. There were desirable and undesirable
features of each tool, however, the LEASAT pliers required less energy to use,
and provided more tactile feedback to the operator, because the hands were
relaxed during most phases of connector positioning and engagement. The major
drawback to the LEASAT pliers for this application was that the tool does not
indicate correct settings for specific connector sizes, so it was easy to
clamp too tightly on a connector ring and permanently deform the ring.
Several connector rings on the mockup were deformed during the test series to
a degree that significantly interfered with connector reattachment.
Specific recommendations for the SAMS In-line Connector Connector Pliers are:
(1) Jaws should be positioned so that, when the pliers is closed on a
connector, the connector is held with its long axis parallel, and as
nearly as possible, coincident with the long axis of the body of the
tool. The two objectives of this feature are first, to permit use of
the tool long axis as the primary alignment aid when reinstallating
connectors, and second, to allow the end of the tool long axis
opposite the connector to rotate in one spot during connector
mate/demate, rather than describing a circle.
(2) A "T-bar" handle, as incorporated on the LEASAT tool, should be
included, but rotated 90° from the plane of travel of the vise grip
4-23
LMSC-F104866 Vol. V
Fig. 4-10 HST-Zero Degree Connector Pliers
4-24
LMSC-F104866 Vol. V
Fig. 4-11 LEASAT Vise Grip Connector Tool
4-25
LMSC-F104866 Vol. V
(To Be Supplied)
Fig. 4-12 Recommended Cannon Connector Tool Jaw Configuration
4-26
LMSC-F104866 Vol. V
handle, to provide a clear access path to the vise grip handle.
(3) The tool jaws should be designed to permit visibility of the
connector ring during as much of the tnate/demate rotational cycle as
possible, to permit verification of non-slippage. This
recommendation is illustrated conceptually by Fig. 4-12.
(4) The tool should incorporate spring-loaded shoulders to aid in
properly positioning the jaws on the connector ring. The shoulders
incorporated in both the HST zero degree and the 90° connector
pliers (see Fig. 4-13) worked very well for this function.
(5) The tool should incorporate a feature to allow presetting of the jaws
to the specific connector size prior to gripping the connector ring.
A vernier feature with substantial built-in friction should be
incorporated to permit adjusting the preset position if required to
accommodate tool wear and tolerance buildup.
(6) The tool should incorporate 2 jaw settings for each connector size -
a "soft" grip setting which allows the crewmember to hold the tool
with one hand while inserting the pigtail half of the connector into
the jaws, and a "hard" grip setting which grips the ring securely for
the mate/demate rotation. The soft position should be maintained by
detent only - not a separate mechanical stop which must be released
to go to the hard grip position. The soft versus hard positions
should be readily identifiable visually.
(7) The tether ring should be designed to rotate around the tool shaft to
eliminate tether "wind-up". The ring should only have one degree of
freedom (rotation about tool long axis) to facilitate tether
attachment.
4.1.5.2 90° Connector Pliers: The function of this tool is to install and
remove closely spaced cannon-type electrical connectors (where spacing and/or
access limitations preclude gloved hand access), when the access is
4-27
LMSC-F104866 Vol. V
Fig. 4-13 Spring Loaded Shoulders in the Jaws of the 90° Connector Pliers
4-28
LMSC-F104866 Vol. V
Fig. 4-14 HST 90° Connector Pliers
4-29
LMSC-F104866 Vol. V
perpendicular to the connector long axis.
The HST 90° Connector Pliers, (Fig. 4-14) was evaluated for this
application. The tool was otherwise similar in design to the HST Zero Degree
Connector Pliers; comments 3, 4, 5, and 6 from the previous section (Zero
Degree Connector Pliers) also apply to the 90° Pliers.
4.1.5.3 Zero Degree Coax Connector Pliers. The purpose of this type of tool
is to remove and reinstall small, single wire coax connectors requiring
multiple turns. No tools of this type were available for evaluation during
the CSTS test; the small connectors were removed and replaced largely by
hand. Manual operations resulted in a high degree of fatigue, significant
glove wear, a tendency to "wind-up" the connector wire, and significant risk
of glove-induced damage to adjacent single wire connectors. Observations and
suggestions made during the test resulted in the development of the following
recommendations of design requirements for a zero-degree coax connector pliers.
(1) The tool should incorporate a locking feature to maintain the grip on
the connector.
(2) The locking feature should include a "soft" grip position to permit
inserting the pigtail half of the connector in the jaws with one hand
while holding the tool in the other hand, and a "hard" grip position
for use in turning the connector.
(3) The tool should be capable of multiple 360° turns of the connector,
without removal from the connector, and without wrapping the
connector wire.
(4) The palm wheel used in the ESSEX wrench (Fig. 4.15) should be
considered for this tool to provide a crew interface which permits
multiple turn inputs with minimal wrist/hand/finger energy
expenditure.
4.1.5.4 Coax Connector Hex Head Tool. The objective of this tool is to
4-30
LMSC-F104866 Vol. V
Fig. 4-15 Essex EVA Ratchet Wrench
4-31
LMSC-F104866 Vol. V
Fig. 4-16 Coax Connector Hex Head Tool
4-32
LMSC-F104866 Vol. V
Fig. 4-17 Coax Connector Hex Head Tool
4-33
LMSC-F104866 Vol. V
release/tighten hex-headed fasteners and/or connectors. The tool evaluated
was a simple offset open end wrench with EVA handle and tether ring (Fig.
4-16). Details of the wrench end are shown in Fig. 4-17. The tool was used
to mate and demate very closely spaced coax connectors with hex heads. The
tool performed well as designed; the only significant improvement suggested
was the following:
(1) Addition of a shoulder to the tool head would allow installation of
connectors with the tool, using only one hand. (As evaluated, the
tool requires that the crewmember position the connector with one
hand while tightening with the wrench in the other hand.).
Consideration should be given to locating the shoulder at the
mid-height position in the head of the wrench, so that the wrench can
be used to hold a connector in either direction - this feature would
require increasing the thickness of the head.
4.1.5.5 D Connector Mate and Demate Tools. The objective of these tools was
to aid the removal or replacement of closely-spaced D connectors. The mate
tool evaluated during the CSTS tests is shown on the left in Fig. 4-18; the
demate tool evaluated is shown on the right. Both tools included width adjust
capability (one jaw fixed; the other adjustable between positions 1 and 5,
with detents at each numbered position). Both jaws on each tool were designed
to rotate the full 360° about the attach point to the handle, with detents
in each 90° pisition.
The demate tool worked well as designed. The mate tool, however, proved
difficult to use, largely due to the fact that the tool could not grip the
connector tightly enough to -counter the loads imposed by the wiring harness.
As a result of the CSTS evaluation, the following design recommendations were
developed for a generic D connector mate tool for SAMSS missions:
(1) The requirement for including jaw rotation capability should be
carefully reassessed, and dropped if possible. If the capability can
be justified, it should be designed to require a deliberate,
significant effort, to preclude inadvertent rotation and release of
4-34
LMSC-F104866 Vol. V
Fig. 4-18 "D" Connector Mate and Demate Tools
4-35
LMSC-F104866 Vol. V
the connector during installation.
(2) The jaw spacing should be undersized so that, when the jaws are set
for a specific connector, the jaws must be forced apart at the
connector end to allow the connector to be inserted.
4.1.5.6 Screwdriver. The purpose of the screwdriver was to release and
resecure small captive screws. The screwdriver evaluated during the tests was
a blade type, in the form of an extension designed for use with the ESSEX EVA
ratchet wrench. A set of extensions designed for use with the ESSEX wrench
are shown in Fig. 4-19; the blade screwdriver is shown on the right. A Torque
Tip Drive extension is shown on the left. The ESSEX wrench itself is shown
with a socket extension in Fig. 4-15.
The screwdriver tip was surrounded by a circular shroud to aid the EVA
crewmember in maintaining position on the screwhead. A small coiled spring
section was included just behind the head of the screwdriver to permit
off-axis access to screws. These features are shown in the closeup of the
blade tip (Fig. 4-20).
4.1.5.7 EVA Ratchet Wrench. The EVA ratchet wrench developed by ESSEX is a
manual ratchet modified to enhance utilization in the pressure suit, the
principal modifications are the addition of a palm wheel and an enlarged, more
accessible direction reversing lever. The wrench works well for its intended
purpose, however, the following suggestion would reduce hand fatigue in
extended operation:
(1) Modify palm wheel to include a thumb ring instead of the center
mounted button, to permit operation with thumb and fingers positioned
as shown in Fig. 4-21, as opposed to Fig. 4-22. The extension
release function represented by the center-mounted button would be
incorporated in the thumb ring, or eliminated entirely if the
McTether system is used. The thumb ring would be designed with a
profile low enough to not impede gripping the palm wheel.
4-36
LMSC-F104866 Vol. V
Fig. 4-19 Extensions for the Essex EVA Ratchet Wrench
4-37
LMSC-F104866 Vol. V
Fig. 4-20 Shrouded Screw Driver Blade Tip
4-38
LMSC-F104866 Vol. V
Fig. 4-21 Relaxed Finger Position for Gripping the Palm Wheel
4-39
LMSC-F104866 Vol. V
Fig. 4-22 Palming the Essex Ratchet Wrench
4-40
LMSC-F104866 Vol. V
4.1.6 Test 2: SAMS Designed ORU Conclusions/Recommendations
4.1.6.1 Alignment Aids Large ORU.
The optimum position for the installation and removal of the large ORU placed
the test subjects eyes 9" above the attach bolt of the "sword and scabbard"
system. The test subject could observe, from this position, the insertion of
the blade into the receiving rail. Therefore, initial visual alignment was
not overly difficult. However, test subjects showed some difficulty with the
insertion of the ORU once initial alignment had been completed. The ORU
tended to rotate in three axis about the point of contact between the sword
and scabbard. Much of this can be taken care of with improved interface
design, but some type of physical alignment a<id would be helpful. The fact
that the receptical bay was at an angle away from the crewmember seemed to
cause consistent problems. The test subjects attempted to insert the ORU
straight into the bay, not taking into account that the base structure is
circular and curves away from them. A physical alignment aid on the side of
the ORU opposite the interface system would help solve this problem.
4.1.6.2 Alignment Aids - Small ORU.
With the interface system installed on the side of the receptical bay, the
system alignment was much the same as the large ORU except the motions were
less exagerated due to the smaller physical size of the box. Alignment with
the interface system at the bottom of the bay proved to be very difficult as
this operation (from the higher of the two PFR positions) was completely
blind. Attempts were made using the side of the scabbard, the overall ORU
shape relative to the bay and the back of the ORU relative to the bay as
alignment aids, but to no avail. With the PFR positioned directly below the
bay, alignment was easy, as the test subject could sight directly down the
interface system, but the physical handling of the box was difficult due to
the face it was directly overhead.
Alignment with the top mounted interface system was not quite as difficult,
because the test subject was eye level with the interface system and could see
4-41
LMSC-F104866 Vol. V
the initial alignment.
4.1.6.3 Interface Design.
During the actual physical operation of the "sword and scabbard" system
difficulties were encountered due to damage to the Delron channels of the
scabbard caused by the sword. Also the relatively small contact area of the
interface system allowed too much movement of the box about this one attach
point. To solve these problems, the system should be designed with a broader
base with a much more shallow angle for alignment to avoid the sword catching
the scabbard and causing damage. In order to aid with the alignment problem
mentioned earlier, the redesigned system also allows for angular misalignment
about a vertical axis through the attach point.
4.1.6.4 Crew Aids.
Crew aids are required on both the spacecraft and the ORU itself. During
tests conducted with the interface system side mounted in the bay, test
subjects used the door knob on the adjacent bay door as a handhold during the
insertion and retraction of the ORU. This should be replac«d by a handrail on
the structure between the bays. During the top and bottom mounted runs, the
sides of the bay and the adjacent handrails were used. Still, an optimized
handrail system could be an improvement.
The handholds on the ORU itself should be placed as close to the center line
of the interface system as possible. A handhold on the connector interface
plate of the ORU itself is a possibility.
The flush mounted handholds proved useful only during the tests of the bottom
mounted interface when the test subject was in a position that proved to be
relatively useless for alignment. It is therefore recommended that these
handles be withdrawn from consideration as they are very costly in terms of
internal volume of the ORU.
4-42
LMSC-F104866 Vol. V
4.1.6.5 Crewmember Positioning.
Proper positioning of the EVA crewmember for the SAMSS designed ORU tasks is a
tradeoff between visual alignment and physical handling of the ORU. The
optimum position for the operation of the large ORU was with the foot
restraint offset to the left of the bay and the crewmembers' eyes 9" above the
interface bolt. Handling was actually easier from the next higher position,
but the subjects arms interfered with the visual alingment of the system. The
optimum position for the small ORU was found to be 5 inches higher for
handling reasons. Difficulties with handling occurred with the top and bottom
mounted interfaces because the ORU was in awkward position, such as overhead.
In general, the EVA crewmember should be positioned so the arms can operate
directly in front of the chest area while making.the system can be visually
aligned.
A general observation relative to tests such as the two reported herein is
that effective, efficient testing involving the amount of hardware normally
used in full scale neutral buoyancy tests requires the on-site ability to
respond quickly to numerous needs to modify, reconfigure, repair, or fabricate
equipment items. Although the capability to readily respond to these
requirements exists at MDAC, this need was not adequately provided for by the
current contractual arrangements.
4.2 ROBOTICS TESTS
(To Be Supplied)
4-43
LMSC-F104866 Vol. V, App. A
APPENDIX A ORS PROCEDURES
This section includes the STS-41G Orbital Refueling System (ORS) hydraulic
transfer experiment procedures as adapted by LMSC for the Helmet Mounted
Display/Electronic Documentation Experiment.
A-l
LMSC-F104866 Vol. V, App. A
(This page intentionally left blank)
A-2
LMSC-F104866 Vol. V, App. A
LMSC SAMS ORS PROCEDURE TAPE (JAN. 1987)
STEP
NO. TASK
1. Grasp hand knob.
2. Fold back thermal covers.
3. Egress foot restraint.
4. Unlatch and stow landing brace.
5. Remove tool cover.
6. Stow tool cover.
7. Ingress foot restraint.
8. Locate seal verification tool on map.
9. Tether seal verification tool - left ORS tether ring.
10. Check pressure on gauge.
11. Restow and untether seal verification tool.
12. Locate wire clippers on tool map.
13. Tether wire clippers to wrist tether ring.
14. Clip and bend away safety wires on dust cover.
15. Restow and untether wire clippers.
16. Locate dust cap removal tool on map.
17. Wrist tether dust cap removal tool.
18. Remove dust cap with 6-3/4 turns CCW.
19. Restow and untether dust cap removal tool.
20. Locate ball valve on tool map.
21. Tether both ball valve caps to right ORS tether ring.
22. Unstow ball valve and remove small cap.
23. Install ball valve on uncovered port - ST/CW - making sure safety
catch engages.
24. Close ball valve.
Raise gold handle.
25. Remove silver cap from end of ball valve.
26. Tether seal verification tool (verbal instructions on which tethers
to use).
27. Remove red cap. Put tethered cap to left of tool tray. A-3
LMSC-F104866 Vol. V, App. A
LMSC SAMS ORS PROCEDURE TAPE (JAN. 1987)
28. Install tool on ball valve - 6T CW until tight.
29. Release safety.
30. Turn green knob CCW as far as possible.
31. Check pressure gauge.
32. Open ball valve.
Pull gold handle down.
33. Check pressure gauge.
34. Close ball valve.
Raise gold handle.
35. Turn green knob CW to original position.
36. Reengage safety.
Turn bolt CW/90°.
37. Remove seal verif. tool - 6T CCW.
38. Replace end cap.
Res tow and untether.
39. Lower then raise gold handle on ball valve.
40. Locate nut retainer tool on tool map.
41. Tether nut retainer tool to wrist tether ring.
42. Unstow and tether end cap to left ORS tether ring.
43. Remove protective cap.
44. Slide red collar away from knob.
45. Thread red collar onto ball valve - 4-1/2 T CW.
46. Open ball valve.
Pull gold handle down.
47. Insert tool shaft thru ball valve.
48. Make 6T CCW and retract tool shaft. Important to count turns here.
49. Close ball valve.
Raise gold handle.
50. Remove tool 4-1/2 T CCW on red collar.
51. Check tool end for nut and cap
with nut and cap.
without nut and cap.
A-4
LMSC-F104866 Vol. V, App. A
LMSC SAMS ORS PROCEDURE TAPE (JAN. 1987)
52. Replace tool cap.
53. Untether cap.
54. Restow and untether tool from wrist tether ring.
55. Locate multipurpose tool on tool map.
56. Tether multipurpose tool cap to left ORS tether ring.
57. Remove tool cap.
58. Slide large blue collar away from tool's hose.
59. Thread collar onto ball valve 4-1/2 T CW or until tight.
60. Open ball valve.
Pull gold handle down.
61. Insert tool shaft thru ball valve until contact is made/felt.
62. Rotate knurled handle 3-1/2 T CW or until tight.
63. Push knurled handle to engage red tabs over tool lip.
"Procedure Complete"
A-5
LMSC-F104866 Vol. V, App. A
(This page intentionally left blank)
A-6
LMSC-F104866 Vol. V, App. B
APPENDIX B Helmet Mounted Display Test Data
This section includes the data from each HMD test run during the first neutral buoyancy test series.
B-l
LMSC-F104866 Vol. V, App. B
(THIS PAGE INTENTIONALLY LEFT BLANK)
B-2
LMSC-F104866 Vol • v,
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B-27
LMSC-F104866
Vol. V, App. C
APPENDIX C: Transcripts of Simulation Master Tapes
This section includes the transcripts of all neutral buoyancy test master
tapes analyzed in detail in the preparation of this report.
C-l
LMSC-F104866
Vol. V, App. C
(This page intentionally left blank)
C-2
LMSC-F104866 Vol. V, App. C
HMD/ELECTRONIC DOCUMENTATION TEST TRANSCRIPT
TEST # _1 . USAF Subject: Untrained, With ED
TAPE #3 - 2/5/87 P.M.
TAPE
COUNTER EVENT TIME
0045 Subject at top of steps
Ready for arm weight
0326 Start pressurization
0398 Pressure 3.5 PSI
Start down stairs
0645 Helmet submerges 13:54:00
0755 Switch to underwater
camera. Subject on
lower platform being ballasted.
Very murky water.
1195 Ballasting complete. 14:01:00
Starting translation to ORS.
1260 Start foot restraint ingress
1300 Bumped mirror ingressing
foot restraints.
1400 Readjusting foot 14:05:00
restraint 12" lower
C-3
TAPE
COUNTER
TAPE #3 - 2/5/87 P.M.
Continued
EVENT
1560 Channel on foot
restraint base broken
LMSC-F104866 Vol. V, App. C
TIME
1893 Subject returns to foot restraint
1964 GRASP HAND KNOB
o Ignored because already
in restraint
14:14:00
1970 FOLD BACK THERMAL COVERS 14:14:15
14:15:11
2030 INGRESS FOOT RESTRAINT
o Ignored - already in restraint
14:15:23
2040 UNLATCH AND STOW LANDING BRACE 14:13:29
14:15:46
2055 REMOVE TOOL COVER
o Requested replay of
tape sequence
o Also received verbal
assistance from test conductor
14:15:47
14:17:05
C-4
TAPE #3 - 2/5/87 P.M.
Continued
LMSC-F104866 Vol. V, App. C
TAPE
COUNTER
2130
EVENT
STOW TOOL COVER
o Did egress restraints
to stow cover. Used
right hand on cover,
left hand to stabilize
TIME
14:17:06
14:18:09
2190 INGRESS FOOT RESTRAINTS 14:18:10
14:10:30
2195 LOCATE SEAL VERIFICATION TOOL 14:18:31
14:18:44
2220 TETHER SEAL VERIFICATION TOOL
o Subject indicated he
did not understand map;
therefore did not know
where tool was located.
o Requested replay of map.
Map indication of 2 tools
confused subject
2285 TETHER SEAL VERIFICATION TOOL
o Subject missed instruction to
put left ORS tether through
loop at left.
14:18:45
14:19:57
14:18:58
14:20:55
C-5
TAPE
COUNTER
TAPE #3 - 2/5/87 P.M.
Continued
EVENT
LMSC-F104866 Vol. V, App. C
TIME
2340 CHECK PRESSURE ON GAUGE 14:21:05
14:21:13
2350 RESTOW AND UNTETHER 14:21:14
14:21:28
2365 LOCATE WIRE CLIPPERS 14:21:29
14:21:47
2380 TETHER WIRE -CLIPPERS WITH
WRIST TETHER
o 14 seconds lost while
diver released wrist
tether which had
inadvertantly been left
installed upon itself.
14:21:48
14:22:22
2410 CLIP AND BEND AWAY SAFETY WIRES
ON DUST COVER
14:22:23
14:23:06
2435 RESTOW AND UNTETHER WIRE CLIPPERS 14:23:07
14:23:26
2465 LOCATE DUST CAP REMOVAL TOOL 14:23:27
14:23:33
2473 WRIST TETHER DUST CAP REMOVAL TOOL 14:23:39
14:23:46
C-6
TAPE
COUNTER
TAPE #3 - 2/5/87 P.M.
Continued
EVENT
LMSC-F104866 Vol. V, App. C
TIME
2484 REMOVE DUST CAP WITH 6-3/4
TURNS CCW
14:23:47
14:25:18
2561 RESTOW REMOVAL TOOL WITH
DUST CAP AND UNTETHER
14:25:19
14:26:11
2606 LOCATE BALL VALVE
o Subject required replay of map to
find ball valve
262 5 TETHER 2 BALL VALVE CAPS
TO RIGHT ORS TETHER
o T. C. gave verbal warning
about safety tab
2707 UNSTOW BALL VALVE AND
REMOVE SMALL CAP
o Subject asked if small cap
is removed by unscrewing
2795 INSTALL BALL VALVE ON
UNCOVERED PORT - 5T/CW
o Safety catch did not
engage. Diver secured it.
14:26:12
14:26:34
14:26:35
14:28:19
14:28:20
14:30:07
14:30:08
14:32:11
2895 CLOSE BALL VALVE
RAISE GOLD HANDLE
14:32:12
14:32:32
C-7
TAPE #3 - 2/5/87 P.M.
Continued
LMSC-F104866 Vol. V, App. C
TAPE
COUNTER EVENT TIME
2910 REMOVE SILVER CAP
FROM END OF BALL VALVE
14:32:33
14:33:16
2945 TETHER SEAL VERIFICATION TOOL
o Subject requested hold after
verbal instruction to tether
first cap
o When subject retrieved tether
and prepared to attach first
tether ring, he remembered wrong end.
14:33:17
14:34:46
3015 REMOVE RED CAP. PUT
TETHERED CAP TO LEFT OF TOOL TRAY
14:34:47
14:35:29
3045 INSTALL TOOL ON BALL VALVE.
6T CW UNTIL TIGHT
14:35:30
14:36:20
3086 RELEASE SAFETY 14:36:21
14:36:28
3090 TURN GREEN KNOB
CCW AS FAR AS POSSIBLE
14:36:29
14:36:43
3105 CHECK PRESSURE GAUGE 14:36:44
14:36:49
3110 OPEN BALL VALVE
PULL GOLD HANDLE DOWN
14:36:50
14:37:02
C-8
TAPE
COUNTER
TAPE #3 - 2/5/87 P.M.
Continued
EVENT
LMSC-F104866 Vol. V, App. C
TIME
3120 CHECK PRESSURE GAUGE 14:37:03
14:37:13
3130 CLOSE BALL VALVE
RAISE GOLD HANDLE
o Subject asked for clarification -
"was it the green handle or the
gold handle?"
3135 TURN GREEN KNOB CW
TO ORIGINAL POSITION
o Subject was asked to double check
safety engaged - it was not.
14:37:14
14:37:24
14:37:25
14:37:56
3150 REMOVE SEAL VERIFICATION TOOL 14:37:57
14:38:33
3190 REPLACE END CAP.
RESTOW AND UNTETHER
14:38:34
14:39:53
3250 LOWER - THEN RAISE GOLD HANDLE
ON BALL VALVE
14:39:54
14:40:12
3260 LOCATE NUT RETAINER TOOL 14:40:13
14:40:16
3265 TETHER NUT RETAINER TOOL TO WRIST
TETHER
14:40:17
14:40:50
C-9
TAPE #3 - 2/5/87 P.M.
Continued
LMSC-F104866 Vol. V, App. C
TAPE
COUNTER EVENT TIME
3290 UNSTOW AND TETHER END CAP TO
LEFT ORS TETHER
14:40:51
14:41:29
o subject did not put tether thru
left tether ring
3320 REMOVE PROTECTIVE CAP 14:41:30
14:42:01
o subject required additional verbal
clarification of how to remove cap
3345 SLIDE RED COLLAR AWAY FROM KNOB 14:42:02
14:42:31
Thread read collar onto ball
valve - 4-1/2 T CW
combined with previous step
3365 OPEN BALL VALVE
PULL GOLD HANDLE DOWN
14:42:32
14:42:58
3385 INSERT TOOL SHAFT THRU
BALL VALVE
14:42:59
14:43:11
3390 MAKE 6T CCW
RETRACT TOOL SHAFT
14:43:12
14:44:38
C-10
TAPE
COUNTER
TAPE #3 - 2/5/87 P.M.
Continued
EVENT
b T. C. volunteered need
to rotate handle a bit
to make sure tool
is seated on nut.
o T. C. also added that
it is important to
count turns as there is
no other way of verifying
that nut is loose.
LMSC-F104866 Vol. V, App. e
TIME
3455 CLOSE BALL VALVE
RAISE GOLD HANDLE
14:44:39 -
14:44:51
3465 REMOVE TOOL 4 1/2 T
CCW ON RED COLLAR
14:44:52 -
14:45:10
3480 CHECK END OF TOOL FOR
NUT
14:45:11 -
14:45:20
3490 REPLACE TOOL PROTECTIVE
CAP
14:45:21 -
14:46:06
3520 UNTETHER CAP 14:46:07 -
14:46:47
RESTOW AND UNTETHER TOOL Accomplished
jointly
with
previous
task
C-ll
TAPE
COUNTER
TAPE #3 - 2/5/87 P.M.
Continued
EVENT
LMSC-F104866 Vol. V, App. C
TIME
3545 LOCATE MULTIPURPOSE TOOL 14:46:48
14:46:54
3550 TETHER MULTIPURPOSE TOOL
CAP TO LEFT ORS TETHER
14:46:55
14:47:32
o Subject did not route
tether thru left tether loop
3580 REMOVE TOOL CAP 14:47:33
14:48:19
3583 END OF TAPE
C-12
TAPE
COUNTER
TAPE #3 - 2/5/87 P.M.
Continued
EVENT
LMSC-F104866 Vol. V, App. C
CONTINUE WITH SMS NB 8701 TAPE #2 (2/5/87)
TIME
0050 SLIDE LARGE BLUE COLLAR
AWAY FROM TOOL'S HOSE
14:48:20
14:48:42
0085 THREAD COLLAR ONTO BALL VALVE
4 1/2 T CW OR TIGHT
14:48:43
14:49:05
o Subject erroneously reported that
collar was tight. Corrected by
diver.
0125 OPEN BALL VALVE
PULL GOLD HANDLE DOWN
14:49:07
14:49:32
0163 INSERT TOOL SHAFT THRU
BALL VALVE UNTIL CONTACT
14:49:48
14:51:34
o Subject stopped short,
reporting contact,
o Requested to push in
fartherby test conductor,
o Inadvertently pushed too far,
corrected by diver.
0345 ROTATE KNURLED HANDLE
3 1/2 T CW OR TIGHT
14:51:35
14:52:07
C-13
LMSC-F104866 Vol. V, App. C
TAPE #3 - 2/5/87 P.M.
Continued
TAPE
COUNTER EVENT TIME
CONTINUE WITH SMS NB 8701 TAPE #2 (2/5/87) (Cont'd)
0390 PUSH TO ENGAGE RED 14:52:08
TABS OVER LIP 14:52:12
PROCEDURE COMPLETE
C-14
HMD/ELECTRONIC DOCUMENTATION TEST TRANSCRIPT TEST # . USAF Subject: ORS-Trained, No ED
TAPE #8 - 2/6/87 A.M.
TAPE COUNTER EVENT TIME
0032 Topside, Subject in donning station 8:41:30
0210 Out of donning station
0545 Starting to pressurize
0615 Starting down steps
0860 Starting to lower platform
1100 Switch to underwater camera. Water murky
1300 Divers transfer subject to ORS work station
1374 Subject arrives at ORS Workstation. Thermal blanket hardware in background
1440 Subject reports "in foot restraints. Foot restraint height ok, but lower than last time by 5-6 inches."
1550 Good rear shot of subject in ORS Workstation
1571 Test begins. "OK - Let's Go For It" 9:02:03
1631 Thermal Blankets Removed 9:03:01
o Landing bace was was unlatched and stowed in approximately 3 seconds before side panels were folded back.
1646 Tool Cover Stowed 9:03:34
o Good whole body shot of subject exiting foot restraints to stow cover
1710 Foot Restraints Ingressed 9:04:20
o Subject skipped seal verification tool pressure check
o Subject skipped simulated safety wire CVT
1775 Tether Attached to Dusp Cap 9:04:37 Remove1 Tool
C-15
1815
1863
1965
2001
2118
2122
2151
2209
2228
2281
2304
2309
2311
2315
2316
2318
2339
2365
2383
2451
2465
Dust Cap Removed 9:06:08
Removal Tool And CAp Stowed 0:06:50
o Cap stowed in trash bag - subject was following Honeywell procedure.
2 Ball Valve Caps Tethered To Right ORS Tether 9:08:44
o T.C. reminded subject of procedure - he had used wrist tether
Small Cap Removed From Ball Valve 9:09:23
Ball Valve Installed On Uncovered Port 9:11:28
o Subject verified safety catch properly engaged
Ball Valve Closed 9:11:34
Silver CAp Removed From End Of Ball Valve 9:12:08
Tether Seal Verification Tool 9:13:10
Red Cap Removed From Seal Verification Tool 9:13:30
Seal Verification Tool Installed On Ball Valve 9:14:33 —"I »■ ' ' ' ' t ™ ^^^^—ll-l.ll— II II II I ■ !■■■— !■■■■■ .1—111 —-II -I
Safety Released 9:14:57
Green Knob Rotated Fully Open 9:15:04
Pressure Checked 9:15:04
Ball Valve Opened 9:15:11
Pressure Checked 9:15:13
Ball Valve Closed 9:15:28
Green Knob Turned CW Original Position 9:15:41
Safety Bolt Reengaged 9:16:10
Seal Verification Tool Removed 9:16:34
End Cap Replaced Restowed And Untethered 9:17:51
Ball Valve Vented By Lowering, Then Raising Gold Handle 9:18:08
o Subject forgot this step, was reminded by T.C. (step may not be in VIMAD procedures on which he was trained)
C-16
2475 Nut Retainer Tool Tethered To Wrist . 9:18:20
2505 Tool Unstowed, End CAp Tethered To Left ORS Tether 9:18:54
2515 Protective Cap Removed 8:19:08
2519 Red Collar Slid Away From Knob 9:19:12
2537 Red Collar Threaded Onto Ball Valve 9:19:33
2539 Ball Valve Opened 9:19:38
2552 Tool Shaft Inserted Through Ball Valve 9:19:51
2572 Nut Released And Tool Retracted 9:20:18
2576 Ball Valve Closed 9:20:22
2588 Tool Removed 9:20:35
2591 Nut Verified 9:20:40
2608 Tool Cap Replaced 9:21:00
2613 Untether Cap 9:21:06
2630 Tool Restowed And Untethered 9:21:25
2663 Multipurpose Tool CAp Tethered To Left ORS Tether 9:22:06
2681
2684
2700
2703
2709
2724
2726
2760
3385
o Subject requested and received instructions on which tether to use.
Tool Cap Removed
Blue Collar Slid Away From Hose End
Tool Collar Installed On Ball Valve
Ball Valve Opened
Tool Shaft Inserted Until Contact
Knurled Handle Rotated CW Until Tight
Red Tabs Pushed To Engage Position
Subject begins to reconfigure ORS, since second subject was not ready.
Start pressurizing next subject video still shows first subject reconfiguring ORS
9:22:28
9:22:32
9:22:51
9:22:55
9:23:02
9:23:19
9:23:23
:30:00
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3420
3540
3575
3600
3630
Subject 2 pressurized
First subject reinstalls thermal curtains
ORS Reconfiguration complete
First subject practices foot restraint ingress/egress
End of Tape
9:38:38
9:40:00
9:43:10
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LMSC-F104866 Vol. V, App. C
HMD/ELECTRONIC DOCUMENTATION TEST TRANSCRIPT
TEST # 1 . USAF Subject: ED Run With VIMAD
TAPE #10 - 2/6/87 A.M.
TAPE
COUNTER EVENT TIME
0083 Tape begins. LMSC diver is reconfiguring ORS
0304 Reconfiguration complete, LMSC diver gives thumbs up 10:38:24
0300 Task starts, using VIMAD procedure 10:38:24
0310 Task 1: Foldback Thermal Curtains 10:38:38
10:30:24
0419 Task 2: Release Tool Supports 10:39:25
10:40:10
0470 Task 3: Remove and stow tool box access cover 10:40:11
10:41:10
o Subject commented that pause in the VIMAD tape
seemed to be in the wrong page - you pull the
cable and unlatch it, and then you have to hold
the cable, exerting pressure, while you asked the
machine to continue.
0590 o Subject commented he can see but can't read the text,
because of the size, primarily and the scratches.
o Subject like the steps, as opposed to the Lockheed tape
telling you step by step what to do.
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LMSC-F104866 Vol. V, App. C
0616 Task 4: Remove dust cap 10:41:48
10:44:28
o Subject commented that he likes the fact that
it automatically stops after each step, and you
have to tell it to continue
0818 Task 5: Install Ball Valve Moving 10:44:35
10:45:45
o Subject commented that tape should not require
another "continue" after the title slide. If
you have already said "continue" to get it to
start into the next subset of procedures, you
obviously are ready for it to proceed and should
wot have to give another "continue" command after
the fifth slide.
1110 Split screen appears, showing VIMAD signal to subject
as the inset, and subject at work.
1180 Concern over ait leak from LTA
1236 Inset oh^^ltt-SCTeewPaised for athletic purposes
1365 Task 6: Eonduct leak check ^ - 10:52:32
7 rf: 11:01:50
o Subject commented that he could not tell on
tape where spanner wrench was located in tool
tray.
o Also tape instructed subject to use left side
tether for spanner wrench. Left side tether is
still attached to seal verification tool.
C-20
LMSC-F104866 Vol. V, App. C
Task 7: Remove Satellite Valve HEX Nut and Cap 11:01:51
11:06:30
o After play through of first subtask subject asked
for repeat.
(task completion corresponds to"Restow and Unthether
Tool" step following use of nut retainer tool on
Lockheed procedure)
2210 Video inset went black - changing optical discs 11:07
2220 Task 8: Install Multipurpose Tool 11:07:10
11:10:29
o Subject missed step "place feedline to right
of tool", resulting in substantial twisting
of feedline when tool cover was replaced, in
task 10 below.
2390 Task 9: Open Satellite Valve 11:10:30
11:11:37
o Hardware does not actually operate as procedures
indicate.
2455 Task 10: Configure Worksite For Reentry 11:11:38
11:18:52
o Subject required assistance of diver to understand
how to operate landing brace locking fenture
2813 Task completed
2820 Subject exits ORS workstation and screen goes black (Good
leaving "procedure complete" in inset. shot)
C-21
LMSOF104866 Vol. V, App. C
2885 Helmet surfaces. Switch to top side camera 11:20:27
2970 Discussion of leak in LTA (Jeff Robert) 11:23:00
Subject in water on upper platform.
3025 Subject goes up steps. Subject in donning
station. 11:25:12
End of tape 11:27:03
C-22
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