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The on condition program is described in terms of its effectiveness as a maintenance tool both at the line station as well as at home base by the early detection of engine faults, erroneous instrumentation signals and by verification of engine health. The system encompasses all known methods from manual procedures to the fully automated airborne integrated data system.
This paper presents a historical perspective of the advancement of control technologies for aircraft gas turbine engines. The paper primarily covers technology advances in the United States in the last 60 years (1940 to approximately 2002). The paper emphasizes the pioneering technologies that have been tested or implemented during this period, assimilating knowledge and experience from industry experts, including personal interviews with both current and retired experts. Since the first United States-built aircraft gas turbine engine was flown in 1942, engine control technology has evolved from a simple hydro-mechanical fuel metering valve to a full-authority digital electronic control system (FADEC) that is common to all modern aircraft propulsion systems. At the same time, control systems have provided engine diagnostic functions. Engine diagnostic capabilities have also evolved from pilot observation of engine gauges to the automated on-board diagnostic system that uses mathematical models to assess engine health and assist in post-flight troubleshooting and maintenance. Using system complexity and capability as a measure, we can break the historical development of control systems down to four phases: (1) the start-up phase (1942 to 1949), (2) the growth phase (1950 to 1969), (3) the electronic phase (1970 to 1989), and (4) the integration phase (1990 to 2002). In each phase, the state-of-the-art control technology is described and the engines that have become historical landmarks, from the control and diagnostic standpoint, are identified. Finally, a historical perspective of engine controls in the last 60 years is presented in terms of control system complexity, number of sensors, number of lines of software (or embedded code), and other factors.
The OpenSE Cookbook is an open-sourced collection of patterns, procedures, and best practices targeted for systems engineers who seek guidance on applying model-based and executable systems engineering (MBSE) using SysML. Its content has emerged from the system level modeling effort on the European Framework Program 6 (FP6) and the Thirty Meter Telescope (TMT). The TMT MBSE approach applied the Executable Systems Engineering Method (ESEM) and the open-source Engineering Environment (OpenMBEE) to specify, analyze, and verify requirements of TMT’s Alignment and Phasing System (APS) and the Narrow Field Infrared Adaptive Optics System (NFIRAOS). In these applications, implicit dependencies are made explicit in a formal model through the use of ESEM, OpenMBEE, and SysML modeling constructs. The value proposition for applying this MBSE approach was to establish precise requirements and fine-grained traceability to system designs, and to verify key requirements beginning early in development. The integration of ESEM and the OpenMBEE tooling infrastructure (providing linked-data and web-operability) is a significant added value for the MBSE approach. The APS is responsible for the overall pre-adaptive optics wavefront quality, using starlight to measure wavefront errors and align the TMT optics. In the formally integrated and executable SysML model, simulations are performed to analyze the impact of changed requirements and verify specified constraints for various operational scenarios. The APS team used several modeling patterns to capture information such as the requirements, the operational scenarios, involved subsystems and their interaction points, the estimated or required time durations, and the mass and power consumption. Adaptive optics systems are designed to sense real-time atmospheric turbulence and correct the telescope’s optical beam to remove its effect. The system model for the adaptive optics operational modes was developed to capture sequence behaviors and operational scenarios to run Monte-Carlo simulations for verifying acquisition time, observing efficiency, and operational behavior requirements. The model is particularly useful for investigating the effect of parallelization, identifying interface issues, and re-ordering sequence acquisition tasks. A former version of the Cookbook (which is now updated to MBSE challenges, goals, and lessons learned) included modeling guidelines and conventions for all system aspects, hierarchy levels, and views, which were developed during for the Active Phasing Experiment (APE), an opto-mechatronical system technology demonstrator for the Extremely Large Telescope (ELT). The Cookbook utilizes the above mentioned system models as real-world case-studies to demonstrate and document the applications of the recipes, providing also instructional examples and addressing the available tooling support. The Cookbook is accompanied by a number of SysML models and aodel libraries which facilitate model authoring and maintenance. The Cookbook covers the different aspects of Systems Engineering such as management of Requirements, Design (behavior and structure), Interfaces, Interdisciplinary Integration, Analysis, Trade Studies, and Technical Resources. This paper presents the background, motivation, architecture, and highlights some key content of the Cookbook. For example, interface management, error budget management, requirements verification, Monte Carlo driven analysis, and timing analysis of operational scenarios. The paper discusses how the capabilities of OpenMBEE contributed significantly to the adoption of executable systems engineering.
Kennedy Space Center (KSC) is designing and acquiring a Launch Processing System (LPS), an important part of Ground Support Equipment (GSE), to Support launch site operations in a more efficient way than was done on previous programs. LPS will provide (1) automatic control of GSE and Shuttle systems for test and operations, (2) real time data analysis and information display, and (3) efficient recall of test data and engineering files to support Shuttle ground operations. Modern automation techniques, off-the-shelf components, and modular design are being employed to the maximum to achieve these goals. The cost of acquisition, operations, and maintenance of LPS is of great importance and is considered with each engineering trade.
Past and future progress in the performance of control systems for large, liquid rocket engines typified such as current state-of-the-art, the Shuttle Main Engine (SSME), is discussed. Details of the first decade of efforts, which culminates in the F-1 and J-2 Saturn engines control systems, are traced, noting problem modes and improvements which were implemented to realize the SSME. Future control system designs, to accommodate the requirements of operation of engines for a heavy lift launch vehicle, an orbital transfer vehicle and the aerospace plane, are summarized. Generic design upgrades needed include an expanded range of fault detection, maintenance as-needed instead of as-scheduled, reduced human involvement in engine operations, and increased control of internal engine states. Current NASA technology development programs aimed at meeting the future control system requirements are described.
Causal factors in aviation accidents and incidents related to system/component failure/malfunction (SCFM) were examined for Federal Aviation Regulation Parts 121 and 135 operations to establish future requirements for the NASA Aviation Safety Program s Integrated Vehicle Health Management (IVHM) Project. Data analyzed includes National Transportation Safety Board (NSTB) accident data (1988 to 2003), Federal Aviation Administration (FAA) incident data (1988 to 2003), and Aviation Safety Reporting System (ASRS) incident data (1993 to 2008). Failure modes and effects analyses were examined to identify possible modes of SCFM. A table of potential adverse conditions was developed to help evaluate IVHM research technologies. Tables present details of specific SCFM for the incidents and accidents. Of the 370 NTSB accidents affected by SCFM, 48 percent involved the engine or fuel system, and 31 percent involved landing gear or hydraulic failure and malfunctions. A total of 35 percent of all SCFM accidents were caused by improper maintenance. Of the 7732 FAA database incidents affected by SCFM, 33 percent involved landing gear or hydraulics, and 33 percent involved the engine and fuel system. The most frequent SCFM found in ASRS were turbine engine, pressurization system, hydraulic main system, flight management system/flight management computer, and engine. Because the IVHM Project does not address maintenance issues, and landing gear and hydraulic systems accidents are usually not fatal, the focus of research should be those SCFMs that occur in the engine/fuel and flight control/structures systems as well as power systems.
Recent years have brought about a paradigm shift within NASA and the Space Launch Community regarding the performance of conceptual design. Reliability, maintainability, supportability, and operability are no longer effects of design; they have moved to the forefront and are affecting design. A primary focus of this shift has been a planned decrease in vehicle turnaround time. Potentials for instituting this decrease include attacking the issues of removing, refurbishing, and replacing the engines after each flight. less, it is important to understand the operational affects of an engine on turnaround time, ground support personnel and equipment. One tool for visualizing this relationship involves the creation of a Discrete Event Simulation (DES). A DES model can be used to run a series of trade studies to determine if the engine is meeting its requirements, and, if not, what can be altered to bring it into compliance. Using DES, it is possible to look at the ways in which labor requirements, parallel maintenance versus serial maintenance, and maintenance scheduling affect the overall turnaround time. A detailed DES model of the Space Shuttle Main Engines (SSME) has been developed. Trades may be performed using the SSME Processing Model to see where maintenance bottlenecks occur, what the benefits (if any) are of increasing the numbers of personnel, or the number and location of facilities, in addition to trades previously mentioned, all with the goal of optimizing the operational turnaround time and minimizing operational cost. The SSME Processing Model was developed in such a way that it can easily be used as a foundation for developing DES models of other operational or developmental reusable engines. Performing a DES on a developmental engine during the conceptual phase makes it easier to affect the design and make changes to bring about a decrease in turnaround time and costs.
Engineering drawings of prototype restraint system for repair and maintenance by astronauts under weightless conditions - Vol. 2
Improved gas-path seals are needed for better fuel economy, longer performance retention, and lower maintenance, particularly in advanced, high-performance gas turbine engines. Problems encountered in gas-path sealing are described, as well as new blade-tip sealing approaches for high-pressure compressors and turbines. These include a lubricant coating for conventional, porous-metal, rub-strip materials used in compressors. An improved hot-press metal alloy shows promise to increase the operating surface temperatures of high-pressure-turbine, blade-tip seals to 1450 K (2150 F). Three ceramic seal materials are also described that have the potential to allow much higher gas-path surface operating temperatures than are possible with metal systems.
Comprehensive set of engineering drawings and instructions for installation, operation, repair, and maintenance are available for module that provides hot-air or hot-water needs for residence or commercial building. It can accommodate solar collectors of various sizes and types. It can provide utility, workshop, or storage space, in addition to providing hot water or hot air. Extensive insulation minimizes heat losses in structure and in storage and fluid-handling subsystems.
The conceptual design for an improved gas turbine (IGT) powertrain and vehicle was investigated. Cycle parameters, rotor systems, and component technology were reviewed and a dual rotor gas turbine concept was selected and optimized for best vehicle fuel economy. The engine had a two stage centrifugal compressor with a design pressure ratio of 5.28, two axial turbine stages with advanced high temperature alloy integral wheels, variable power turbine nozzle for turbine temperature and output torque control, catalytic combustor, and annular ceramic recuperator. The engine was rated at 54.81 kW, using water injection on hot days to maintain vehicle acceleration. The estimated vehicle fuel economy was 11.9 km/l in the combined driving cycle, 43 percent over the 1976 compact automobile. The estimated IGT production vehicle selling price was 10 percent over the comparable piston engine vehicle, but the improved fuel economy and reduced maintenance and repair resulted in a 9 percent reduction in life cycle cost.
Support was provided to DOE and NASA in their efforts to inform industry, the public, and Government on the benefits and purpose of the gas turbine programs through demonstrations and exhibits. Tasks were carried out for maintenance, repair, and retrofit of the experimental gas turbine engines being used by NASA in their gas turbine technology programs and in program demonstrations. Limited support testing was conducted at Chrysler in which data were generated on air bearing rotor shaft dynamics, heavy duty variable sheave rubber belts, high temperature elastomer regenerator drive mounting and graphite regenerator seal friction characteristics.
The extensive user involvement in the software development of IPAD and the functionality of the IPAD prototype as viewed by the user are addressed. Although not a production system that can support an ongoing design process, the IPAD prototype is useful for the potential user as well as the interested system designer and is an essential tool for the companies committed to the use of the IPAD system. User refers to the engineer or manager responsible for the design, manufacture, or maintenance of a product, together with those supporting these functions.
The transformation portion of the Hubble Space Telescope (HST) Proposal Entry Processor System converts astronomer-oriented description of a scientific observing program into a detailed description of the parameters needed for planning and scheduling. The transformation system is one of a very few rulebased expert systems that has ever entered an operational phase. The day to day operations of the system and its rulebase are no longer the responsibility of the original developer. As a result, software engineering properties of the rulebased approach become more important. Maintenance issues associated with the coupling of rules within a rulebased system are discussed and a method is offered for partitioning a rulebase so that the amount of knowledge needed to modify the rulebase is minimized. This method is also used to develop a measure of the coupling strength of the rulebase.
A prototype simulation is being developed under contract to the Royal Aerospace Establishment (RAE), Farnborough, England, to assist in the discrimination of artificial space objects/debris. The methodology undertaken has been to link Object Oriented programming, intelligent knowledge based system (IKBS) techniques and advanced computer technology with numeric analysis to provide a graphical, symbolic simulation. The objective is to provide an additional layer of understanding on top of conventional classification methods. Use is being made of object and rule based knowledge representation, multiple reasoning, truth maintenance and uncertainty. Software tools being used include Knowledge Engineering Environment (KEE) and SymTactics for knowledge representation. Hooks are being developed within the SymTactics framework to incorporate mathematical models describing orbital motion and fragmentation. Penetration and structural analysis can also be incorporated. SymTactics is an Object Oriented discrete event simulation tool built as a domain specific extension to the KEE environment. The tool provides facilities for building, debugging and monitoring dynamic (military) simulations.
This presentation will be done using the IMR-Entry (Intelligent Medical Record Entry) system. IMR-Entry is a software program developed as a front-end to our diagnostic consultant software MEDAS (Medical Emergency Decision Assistance System). MEDAS (the Medical Emergency Diagnostic Assistance System) is a diagnostic consultant system using a multimembership Bayesian design for its inference engine and relational database technology for its knowledge base maintenance. Research on MEDAS began at the University of Southern California and the Institute of Critical Care in the mid 1970's with support from NASA and NSF. The MEDAS project moved to Chicago in 1982; its current progress is due to collaboration between Illinois Institute of Technology, The Chicago Medical School, Lake Forest College and NASA at KSC. Since the purpose of an expert system is to derive a hypothesis, its communication vocabulary is limited to features used by its knowledge base. The development of a comprehensive problem based medical record entry system which could handshake with an expert system while creating an electronic medical record at the same time was studied. IMR-E is a computer based patient record that serves as a front end to the expert system MEDAS. IMR-E is a graphically oriented comprehensive medical record. The programs major components are demonstrated.
The Data Systems Dynamic Simulator (DSDS+) is a software tool being developed by the authors to evaluate candidate architectures for NASA's end-to-end data systems. Via modeling and simulation, we are able to quickly predict the performance characteristics of each architecture, to evaluate 'what-if' scenarios, and to perform sensitivity analyses. As such, we are using modeling and simulation to help NASA select the optimal system configuration, and to quantify the performance characteristics of this system prior to its delivery. This paper is divided into the following six sections: (1) The role of modeling and simulation in the systems engineering process. In this section, we briefly describe the different types of results obtained by modeling each phase of the systems engineering life cycle, from concept definition through operations and maintenance; (2) Recent applications of DSDS+. In this section, we describe ongoing applications of DSDS+ in support of the Earth Observing System (EOS), and we present some of the simulation results generated of candidate system designs. So far, we have modeled individual EOS subsystems (e.g. the Solid State Recorders used onboard the spacecraft), and we have also developed an integrated model of the EOS end-to-end data processing and data communications systems (from the payloads onboard to the principle investigator facilities on the ground); (3) Overview of DSDS+. In this section we define what a discrete-event model is, and how it works. The discussion is presented relative to the DSDS+ simulation tool that we have developed, including it's run-time optimization algorithms that enables DSDS+ to execute substantially faster than comparable discrete-event simulation tools; (4) Summary. In this section, we summarize our findings and 'lessons learned' during the development and application of DSDS+ to model NASA's data systems; (5) Further Information; and (6) Acknowledgements.
Acceptance data package - engineering drawings and associated lists for fabrication, assembly and maintenance (cleaning, fluidized bed coating, bounding and staking) motor/encoded solar x-ray imager (SXI) (Aeroflex p/n 16187) were given.