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At least 199 records · Page 11

Thermoplastic Aircraft Manufacturing Model

A manufacturing process to produce 80 single aisle sized thermoplastic composite aircraft a month is presented. Within the Hi-Rate Composite Aircraft Manufacturing (HiCAM) program a baseline aircraft fuselage was designed and modeled based on the Boeing 787 one-piece barrel build, but scaled down to a single aisle aircraft. Key Performance Parameters (KPPs) of recurring cost, non-recurring cost, and weight are calculated from the model. The outcome of this simulation indicated a prohibitively high non-recurring cost, so the thermoplastic team modeled the manufacturing flow for a panelized fuselage concept. The minimum success criteria is a 30% cost reduction and less than two percent increase in weight compared to the baseline aircraft. Automated Fiber Placement (AFP) is used to layup skins, stamp forming is used to make body frames, stringers, and passenger door surround parts. In the model, Co-Fusion was used to consolidate the skin while simultaneously welding on stringers to make stiffened panels. Additional welding technologies were considered to minimize fastener use and a vertical build concept was used for final assembly to reduce factory size. This manufacturing concept for a thermoplastic aircraft indicated a 39% cost and 12% weight savings compared to the baseline. Additional trade studies were conducted using Northrop Grumman’s Automated Stiffener Forming technology to make stringers and stamp forming instead of AFP to make skins.

thermoplastic composites↗

Thermoplastic Composite Aircraft Manufacturing Model

A manufacturing process to produce 80 single aisle sized thermoplastic composite aircraft a month is presented. Within the Hi-Rate Composite Aircraft Manufacturing (HiCAM) program a baseline aircraft fuselage was designed and modeled based on the Boeing 787 one-piece barrel build, but scaled down to a single aisle aircraft. Key Performance Parameters (KPPs) of recurring cost, non-recurring cost, and weight are calculated from the model. The outcome of this simulation indicated a prohibitively high non-recurring cost, so the thermoplastic team modeled the manufacturing flow for a panelized fuselage concept. The minimum success criteria is a 30% cost reduction and less than two percent increase in weight compared to the baseline aircraft. Automated Fiber Placement (AFP) is used to layup skins, stamp forming is used to make body frames, stringers, and passenger door surround parts. In the model, Co-Fusion was used to consolidate the skin while simultaneously welding on stringers to make stiffened panels. Additional welding technologies were considered to minimize fastener use and a vertical build concept was used for final assembly to reduce factory size. This manufacturing concept for a thermoplastic aircraft indicated a 39% cost and 12% weight savings compared to the baseline. Additional trade studies were conducted using Northrop Grumman’s Automated Stiffener Forming technology to make stringers and stamp forming instead of AFP to make skins.

thermoplastic composites↗

Testing First-Order Logic Axioms in AutoCert

AutoCert [2] is a formal verification tool for machine generated code in safety critical domains, such as aerospace control code generated from MathWorks Real-Time Workshop. AutoCert uses Automated Theorem Provers (ATPs) [5] based on First-Order Logic (FOL) to formally verify safety and functional correctness properties of the code. These ATPs try to build proofs based on user provided domain-specific axioms, which can be arbitrary First-Order Formulas (FOFs). These axioms are the most crucial part of the trusted base, since proofs can be submitted to a proof checker removing the need to trust the prover and AutoCert itself plays the part of checking the code generator. However, formulating axioms correctly (i.e. precisely as the user had really intended) is non-trivial in practice. The challenge of axiomatization arise from several dimensions. First, the domain knowledge has its own complexity. AutoCert has been used to verify mathematical requirements on navigation software that carries out various geometric coordinate transformations involving matrices and quaternions. Axiomatic theories for such constructs are complex enough that mistakes are not uncommon. Second, adjusting axioms for ATPs can add even more complexity. The axioms frequently need to be modified in order to have them in a form suitable for use with ATPs. Such modifications tend to obscure the axioms further. Thirdly, speculating validity of the axioms from the output of existing ATPs is very hard since theorem provers typically do not give any examples or counterexamples.

Ahn, Ki Yung↗

MPST Software: grl_pef_check

This innovation is a tool used to verify and validate spacecraft sequences at the predicted events file (PEF) level for the GRAIL (Gravity Recovery and Interior Laboratory, see http://www.nasa. gov/mission_pages/grail/main/index. html) mission as part of the Multi-Mission Planning and Sequencing Team (MPST) operations process to reduce the possibility for errors. This tool is used to catch any sequence related errors or issues immediately after the seqgen modeling to streamline downstream processes. This script verifies and validates the seqgen modeling for the GRAIL MPST process. A PEF is provided as input, and dozens of checks are performed on it to verify and validate the command products including command content, command ordering, flight-rule violations, modeling boundary consistency, resource limits, and ground commanding consistency. By performing as many checks as early in the process as possible, grl_pef_check streamlines the MPST task of generating GRAIL command and modeled products on an aggressive schedule. By enumerating each check being performed, and clearly stating the criteria and assumptions made at each step, grl_pef_check can be used as a manual checklist as well as an automated tool. This helper script was written with a focus on enabling the user with the information they need in order to evaluate a sequence quickly and efficiently, while still keeping them informed and active in the overall sequencing process. grl_pef_check verifies and validates the modeling and sequence content prior to investing any more effort into the build. There are dozens of various items in the modeling run that need to be checked, which is a time-consuming and errorprone task. Currently, no software exists that provides this functionality. Compared to a manual process, this script reduces human error and saves considerable man-hours by automating and streamlining the mission planning and sequencing task for the GRAIL mission.

Call, Jared A.↗

Automated Generation of Fault Management Artifacts from a Simple System Model

Our understanding of off-nominal behavior - failure modes and fault propagation - in complex systems is often based purely on engineering intuition; specific cases are assessed in an ad hoc fashion as a (fallible) fault management engineer sees fit. This work is an attempt to provide a more rigorous approach to this understanding and assessment by automating the creation of a fault management artifact, the Failure Modes and Effects Analysis (FMEA) through querying a representation of the system in a SysML model. This work builds off the previous development of an off-nominal behavior model for the upcoming Soil Moisture Active-Passive (SMAP) mission at the Jet Propulsion Laboratory. We further developed the previous system model to more fully incorporate the ideas of State Analysis, and it was restructured in an organizational hierarchy that models the system as layers of control systems while also incorporating the concept of "design authority". We present software that was developed to traverse the elements and relationships in this model to automatically construct an FMEA spreadsheet. We further discuss extending this model to automatically generate other typical fault management artifacts, such as Fault Trees, to efficiently portray system behavior, and depend less on the intuition of fault management engineers to ensure complete examination of off-nominal behavior.

Spinup and Orient↗

Banning standard cell engineering notebook

A family of standardized thick-oxide P-MOS building blocks (standard cells) is described. The information is presented in a form useful for systems designs, logic design, and the preparation of inputs to both sets of Design Automation programs for array design and analysis. A data sheet is provided for each cell and gives the cell name, the cell number, its logic symbol, Boolean equation, truth table, circuit schematic circuit composite, input-output capacitances, and revision date. The circuit type file, also given for each cell, together with the logic drawing contained on the data sheet provides all the information required to prepare input data files for the Design Automation Systems. A detailed description of the electrical design procedure is included.

Source record↗

Improving Discrete-Sensitivity-Based Approach for Practical Design Optimization

In developing the automated methodologies for simulation-based optimal shape designs, their accuracy, efficiency and practicality are the defining factors to their success. To that end, four recent improvements to the building blocks of such a methodology, intended for more practical design optimization, have been reported. First, in addition to a polynomial-based parameterization, a partial differential equation (PDE) based parameterization was shown to be a practical tool for a number of reasons. Second, an alternative has been incorporated to one of the tedious phases of developing such a methodology, namely, the automatic differentiation of the computer code for the flow analysis in order to generate the sensitivities. Third, by extending the methodology for the thin-layer Navier-Stokes (TLNS) based flow simulations, the more accurate flow physics was made available. However, the computer storage requirement for a shape optimization of a practical configuration with the -fidelity simulations (TLNS and dense-grid based simulations), required substantial computational resources. Therefore, the final improvement reported herein responded to this point by including the alternating-direct-implicit (ADI) based system solver as an alternative to the preconditioned biconjugate (PbCG) and other direct solvers.

Baysal, Oktay↗

Q-Thruster Breadboard Campaign Project

Dr. Harold "Sonny" White has developed the physics theory basis for utilizing the quantum vacuum to produce thrust. The engineering implementation of the theory is known as Q-thrusters. During FY13, three test campaigns were conducted that conclusively demonstrated tangible evidence of Q-thruster physics with measurable thrust bringing the TRL up from TRL 2 to early TRL 3. This project will continue with the development of the technology to a breadboard level by leveraging the most recent NASA/industry test hardware. This project will replace the manual tuning process used in the 2013 test campaign with an automated Radio Frequency (RF) Phase Lock Loop system (precursor to flight-like implementation), and will redesign the signal ports to minimize RF leakage (improves efficiency). This project will build on the 2013 test campaign using the above improvements on the test implementation to get ready for subsequent Independent Verification and Validation testing at Glenn Research Center (GRC) and Jet Propulsion Laboratory (JPL) in FY 2015. Q-thruster technology has a much higher thrust to power than current forms of electric propulsion (~7x Hall thrusters), and can significantly reduce the total power required for either Solar Electric Propulsion (SEP) or Nuclear Electric Propulsion (NEP). Also, due to the high thrust and high specific impulse, Q-thruster technology will greatly relax the specific mass requirements for in-space nuclear reactor systems. Q-thrusters can reduce transit times for a power-constrained architecture.

White, Harold↗

Building the Next Generation Technology Transfer Information System

The Defense Technology Transfer Information System (DTTIS) is a scalable data system built to grow and adapt to changing conditions. It collects information from each technology transfer offices, patent attorneys, innovators, and more. It automates workflows to standardize and streamline technology transfer business rules. This resulting in improved efficiency, standardized processes and reducing errors. DTTIS is a search and reporting engine built on patented NASA's Technology Transfer System (NTTS) core software platform.

Tran, Peter B.↗

Composite Design and Manufacturing Development for Human Spacecrafts

The Structural Engineering Division at the NASA Johnson Space Center (JSC) has begun work on lightweight, multi‐functional pressurized composite structures. The first candidate vehicle for technology development is the Multi‐Mission Space Exploration Vehicle (MMSEV) cabin, known as the Gen 2B cabin, which has been built at JSC by the Robotics Division. Of the habitable MMSEV vehicle prototypes designed to date, this is the first one specifically analyzed and tested to hold internal pressure and the only one made out of composite materials. This design uses a laminate base with zoned reinforcement and external stringers, intended to demonstrate certain capabilities, and to prepare for the next cabin design, which will be a composite sandwich panel construction with multi‐functional capabilities. As part of this advanced development process, a number of new technologies were used to assist in the design and manufacturing process. One of the methods, new to JSC, was to build the Gen 2B cabin with Out of Autoclave technology to permit the creation of larger parts with fewer joints. An 8‐ply pre‐preg layup was constructed to form the cabin body. Prior to lay‐up, a design optimization software called FiberSIM was used to create each ply pattern. This software is integrated with Pro/Engineer to allow for customized draping of each fabric ply over the complex tool surface. Slits and darts are made in the software model to create an optimal design that maintains proper fiber placement and orientation. The flat pattern of each ply is then exported and sent to an automated cutting table where the patterns are cut out of graphite material. Additionally, to assist in lay‐up, a laser projection system (LPT) is used to project outlines of each ply directly onto the tool face for accurate fiber placement and ply build‐up. Finally, as part of the OoA process, a large oven was procured to post‐cure each part. After manufacturing complete, the cabin underwent modal and pressure testing (currently in progress at date of writing) and will go on to be outfitted and used for further ops usage.

Litteken, Douglas↗

A chemical sensor and biosensor based totally automated water quality monitor for extended space flight: Step 1

The result of a literature search to consider what technologies should be represented in a totally automated water quality monitor for extended space flight is presented. It is the result of the first summer in a three year JOVE project. The next step will be to build a test platform at the Authors' school, St. John Fisher College. This will involve undergraduates in NASA related research. The test flow injection analysis system will be used to test the detection limit of sensors and the performance of sensors in groups. Sensor companies and research groups will be encouraged to produce sensors which are not currently available and are needed for this project.

Smith, Robert S.↗

Performance of Two Battery Prognostic Applications used by Two Octocopters for Safe Low Altitude Autonomous Flight Operations

This paper addresses the problem of building trust in online predictions of the remaining available flying time for two different electric Unmanned Aerial Vehicles (eUAVs) powered by lithium-ion-polymer batteries. Flight tests for various automation research missions for the two vehicles were monitored using two on-board battery health management applications to make predictions of the remaining flying time (RFT) for each eUAV and to predict the state of the battery. Playback of the voltage, current and temperature profiles of the battery discharge were used to assess the accuracy of the estimation of the voltage and the charge states of the models as well as the estimate of the RFT. The reference ground truth values were the observed landing time and the measured battery pack resting pack voltage 20 minutes after the flight. The predicted RFT, state of charge (SoC), and state of energy (SoE) were compared with the observed results. Noise values of one standard deviation from the mean values of the internal charge states of the battery model during a reference run were used to vary the states during simulation. One application used an equivalent circuit model of the electrical dynamics of the battery pack, and the other application used a reduced-order electrochemistry model. The variation of the model state components was compared to the variation in the estimate of the RFT and the variation in the SoE to estimate a confidence factor. Variation in the estimates caused by factors affecting the off-line laboratory parameter identification experiments is considered. Variation in the estimates due to environmental factors are discussed.

Assurance↗

Sparse distributed memory: Principles and operation

Sparse distributed memory is a generalized random access memory (RAM) for long (1000 bit) binary words. Such words can be written into and read from the memory, and they can also be used to address the memory. The main attribute of the memory is sensitivity to similarity, meaning that a word can be read back not only by giving the original write address but also by giving one close to it as measured by the Hamming distance between addresses. Large memories of this kind are expected to have wide use in speech recognition and scene analysis, in signal detection and verification, and in adaptive control of automated equipment, in general, in dealing with real world information in real time. The memory can be realized as a simple, massively parallel computer. Digital technology has reached a point where building large memories is becoming practical. Major design issues were resolved which were faced in building the memories. The design is described of a prototype memory with 256 bit addresses and from 8 to 128 K locations for 256 bit words. A key aspect of the design is extensive use of dynamic RAM and other standard components.

Flynn, M. J.↗

An Assessment of IMPAC - Integrated Methodology for Propulsion and Airframe Controls

This report documents the work done under a NASA sponsored contract to transition to industry technologies developed under the NASA Lewis Research Center IMPAC (Integrated Methodology for Propulsion and Airframe Control) program. The critical steps in IMPAC are exercised on an example integrated flight/propulsion control design for linear airframe/engine models of a conceptual STOVL (Short Take-Off and Vertical Landing) aircraft, and MATRIXX (TM) executive files to implement each step are developed. The results from the example study are analyzed and lessons learned are listed along with recommendations that will improve the application of each design step. The end product of this research is a set of software requirements for developing a user-friendly control design tool which will automate the steps in the IMPAC methodology. Prototypes for a graphical user interface (GUI) are sketched to specify how the tool will interact with the user, and it is recommended to build the tool around existing computer aided control design software packages.

Walker, G. P.↗

MISSE-11 Ground Experiment Control

Back during the Apollo missions, when astronauts were being sent to the moon to explore and further scientific knowledge by conducting experiments and collecting samples for scientists back on Earth, they were faced with a surprising problem. It was discovered that the moon’s surface is covered with dust that has electrostatic properties, which would stick to suit and equipment. This hindered the functionality of the astronauts’ space suits, solar panels, optical instruments, among other exposed surfaces due to the jagged geometry of the dust which would damage said equipment. To resolve this issue, the Electrostatics and Surface Physics Laboratory (ESPL) came up with the solution of using an Electrodynamic Dust Shield (EDS)1 that uses electrostatic forces to move particles across a surface. Varieties of this dust shield have been developed for different applications. The purpose of the Materials International Space Station Experiments 11 (MISSE-11) is to experiment a payload that contains the dust mitigation technology to be flown to space for one year and an identical payload will be on earth, under vacuum, in the Electrostatics and Surface Physics Laboratory. The space payload was prepared prior to our arrival and shipped to fly on the International Space Station (ISS). The payload staying on the ground is going to act as a control for the experiment so that we may compare it to the payload that was flown in space. During our time at Kennedy Space Center, we were tasked with building and start testing the ground control unit of the MISSE-11 payload. To complete our task for the ground control unit, we constructed a new vacuum chamber setup and added automated aspects, procured the necessary flight electronics, designed and communicated for the machining of the payload frame, and performed functional and thermal testing on the electronics to the same original operational standards. Some modifications were made where possible, without affecting the performance of the samples, to be efficient with the production of the control unit while keeping important aspects identical. The experiment is now nearly complete, and testing will be starting within the next few weeks.

MISSE↗

Towards Qualification and Certification of Laser Powder Bed Fusion Ti-6Al-4V with In-Situ Process Monitoring and Automated Defect Detection

Qualification and certification of laser powder bed fusion (LPBF) parts are two challenges that must be answered to ensure suitability for critical applications. In-situ monitoring using high frame rate thermal and conventional optical imaging sensors is applied to the LPBF build process. Currently, the large volume of data from such sensors becomes untenable for manual inspection in production environments. This presentation serves to address this in-situ monitoring deficiency in two ways. First, a framework for managing data streams from LPBF process monitoring sensors is described. Second, two candidate image analysis techniques are presented: one is a set of heuristics that are easily interpretable, and the other is an uninterpretable convolutional neural network. These strategies are compared in terms of performance, computational expense, and speed. These methodologies represent platforms for connecting processing conditions to process modeling efforts aligned with the qualification and certification mission for LPBF Ti-6Al-4V components.

Qualification↗

Airspace Technology Demonstration 3 (ATD-3) Multi-Flight Common Route (MFCR) Technology Transfer Document Summary Version 2.0

Airspace Technology Demonstration - 3 (ATD-3) is part of NASA's Airspace Operations and Safety Program (AOSP) - specifically, its Airspace Technology Demonstrations (ATD) Project. ATD-3 is a multi-year research and development effort which proposes to develop and demonstrate automation technologies and operating concepts that enable air navigation service providers and airspace users to continuously assess weather, winds, traffic, and other information to identify, evaluate, and implement workable opportunities for flight plan route corrections that can result in significant flight time and fuel savings in en-route airspace. In order to ensure that the products of this tech-transfer are relevant and useful, NASA has created strong partnerships with the FAA and key industry stakeholders. This summary document and accompanying technology artifacts satisfy the second of three Research Transition Products (RTPs) defined in the Applied Traffic Flow Management (ATFM) Research Transition Team (RTT) Plan. The original transfer, completed in December 2017, consisted of NASA's Multi-Flight Common Route (MFCR) research for efficient route corrections for en-route weather avoidance. This transfer updates the Concept of Operations document to a publicly-available NASA Technical Memorandum. The MFCR concept builds on the experience of the legacy Dynamic Weather Routes (DWR) and focuses on a better balance of potential savings with ATC acceptability, common route corrections options for multiple flights on similar routings, and better use of existing and/or modern automation for communication and coordination of route change options. All of these capabilities are expected to improve system performance significantly in terms of actual delay-reducing clearances issued to flights compared to that of the DWR tool and operating concept.

Tech transfer↗

Supporting the Future Air Traffic Control Projection Process

In air traffic control, projecting what the air traffic situation will be over the next 30 seconds to 30 minutes is a key process in identifying conflicts that may arise so that evasive action can be taken upon discovery of these conflicts. A series of field visits in the Boston and New York terminal radar approach control (TRACON) facilities and in the oceanic air traffic control facilities in New York and Reykjavik, Iceland were conducted to investigate the projection process in two different ATC domains. The results from the site visits suggest that two types of projection are currently used in ATC tasks, depending on the type of separation minima and/or traffic restriction and information display used by the controller. As technologies improve and procedures change, care should be taken by designers to support projection through displays, automation, and procedures. It is critical to prevent time/space mismatches between interfaces and restrictions. Existing structure in traffic dynamics could be utilized to provide controllers with useful behavioral models on which to build projections. Subtle structure that the controllers are unable to internalize could be incorporated into an ATC projection aid.

Davison, Hayley J.↗