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Ares I-X Ground Diagnostic Prototype

Automating prelaunch diagnostics for launch vehicles offers three potential benefits. First, it potentially improves safety by detecting faults that might otherwise have been missed so that they can be corrected before launch. Second, it potentially reduces launch delays by more quickly diagnosing the cause of anomalies that occur during prelaunch processing. Reducing launch delays will be critical to the success of NASA's planned future missions that require in-orbit rendezvous. Third, it potentially reduces costs by reducing both launch delays and the number of people needed to monitor the prelaunch process. NASA is currently developing the Ares I launch vehicle to bring the Orion capsule and its crew of four astronauts to low-earth orbit on their way to the moon. Ares I-X will be the first unmanned test flight of Ares I. It is scheduled to launch on October 27, 2009. The Ares I-X Ground Diagnostic Prototype is a prototype ground diagnostic system that will provide anomaly detection, fault detection, fault isolation, and diagnostics for the Ares I-X first-stage thrust vector control (TVC) and for the associated ground hydraulics while it is in the Vehicle Assembly Building (VAB) at John F. Kennedy Space Center (KSC) and on the launch pad. It will serve as a prototype for a future operational ground diagnostic system for Ares I. The prototype combines three existing diagnostic tools. The first tool, TEAMS (Testability Engineering and Maintenance System), is a model-based tool that is commercially produced by Qualtech Systems, Inc. It uses a qualitative model of failure propagation to perform fault isolation and diagnostics. We adapted an existing TEAMS model of the TVC to use for diagnostics and developed a TEAMS model of the ground hydraulics. The second tool, Spacecraft Health Inference Engine (SHINE), is a rule-based expert system developed at the NASA Jet Propulsion Laboratory. We developed SHINE rules for fault detection and mode identification. The prototype uses the outputs of SHINE as inputs to TEAMS. The third tool, the Inductive Monitoring System (IMS), is an anomaly detection tool developed at NASA Ames Research Center and is currently used to monitor the International Space Station Control Moment Gyroscopes. IMS automatically "learns" a model of historical nominal data in the form of a set of clusters and signals an alarm when new data fails to match this model. IMS offers the potential to detect faults that have not been modeled. The three tools have been integrated and deployed to Hangar AE at KSC where they interface with live data from the Ares I-X vehicle and from the ground hydraulics. The outputs of the tools are displayed on a console in Hangar AE, one of the locations from which the Ares I-X launch will be monitored. The full paper will describe how the prototype performed before the launch. It will include an analysis of the prototype's accuracy, including false-positive rates, false-negative rates, and receiver operating characteristics (ROC) curves. It will also include a description of the prototype's computational requirements, including CPU usage, main memory usage, and disk usage. If the prototype detects any faults during the prelaunch period then the paper will include a description of those faults. Similarly, if the prototype has any false alarms then the paper will describe them and will attempt to explain their causes.

Schwabacher, Mark↗

Development of a Model Based Technique for Gear Diagnostics using the Wigner-Ville method

Imperfections in gear tooth geometry often result from errors in the manufacturing process or excessive material wear during operation. Such faults in the gear tooth geometry can result in large vibrations in the transmission system, and, in some cases, may lead to early failure of the gear transmission system. This report presents the study of the effects of imperfection in gear tooth geometry on the dynamic characteristics of a gear transmission system. The faults in the gear tooth geometry are modeled numerically as the deviation of the tooth profile from its original involute geometry. The changes in gear mesh stiffness due to various profile and pattern variations are evaluated numerically. The resulting changes in the mesh stiffness are incorporated into a computer code to simulate the dynamics of the gear transmission system. A parametric study is performed to examine the sensitivity of gear tooth geometry imperfections on the vibration of a gear transmission system. The parameters variations in this study consist of the magnitude of the imperfection, the pattern of the profile variation, and the total number of teeth affected. Numerical results from the dynamic simulations are examined in both the time and the frequency domains. A joint time-frequency analysis procedure using the Wigner-Ville Distribution is also introduced to identify the location of the damaged tooth from the vibration signature. Numerical simulations of the system dynamics with gear faults were compared to experimental results. An optimal tracker was introduced to quantify the level of damage in the gear mesh system. Conclusions are drawn from the results of this numerical study.

Choy, F.↗

Physics of the Inner Heliosphere 1-10 Rs: Plasma Diagnostics and Models

While the mechanisms responsible for the solar corona and the high-speed solar wind streams are still unknown, model computations offer means of predicting the properties of such mechanisms in light of the empirical constraints currently available. Modeling and data analysis efforts were aimed at understanding the plasma properties of the acceleration of the solar wind, its filamentary nature, and the conditions needed to account for a rapidly accelerating solar wind, reaching its terminal speed within 10 R(sub s). A sequence of models ranging from steady one-fluid descriptions of the solar wind to multi-fluid time-dependent models were developed. Plasma diagnostics evolved from the analysis of data acquired from Skylab to SOHO, and complemented by ground-based observations.

Habbal, Shadia R.↗

Knowledge-based diagnosis for aerospace systems

The need for automated diagnosis in aerospace systems and the approach of using knowledge-based systems are examined. Research issues in knowledge-based diagnosis which are important for aerospace applications are treated along with a review of recent relevant research developments in Artificial Intelligence. The design and operation of some existing knowledge-based diagnosis systems are described. The systems described and compared include the LES expert system for liquid oxygen loading at NASA Kennedy Space Center, the FAITH diagnosis system developed at the Jet Propulsion Laboratory, the PES procedural expert system developed at SRI International, the CSRL approach developed at Ohio State University, the StarPlan system developed by Ford Aerospace, the IDM integrated diagnostic model, and the DRAPhys diagnostic system developed at NASA Langley Research Center.

Atkinson, David J.↗

Knowledge-based diagnosis for aerospace systems

The need for automated diagnosis in aerospace systems and the approach of using knowledge-based systems are examined. Research issues in knowledge-based diagnosis which are important for aerospace applications are treated along with a review of recent relevant research developments in Artificial Intelligence. The design and operation of some existing knowledge-based diagnosis systems are described. The systems described and compared include the LES expert system for liquid oxygen loading at NASA Kennedy Space Center, the FAITH diagnosis system developed at the Jet Propulsion Laboratory, the PES procedural expert system developed at SRI International, the CSRL approach developed at Ohio State University, the StarPlan system developed by Ford Aerospace, the IDM integrated diagnostic model, and the DRAPhys diagnostic system developed at NASA Langley Research Center.

Atkinson, David↗

An architecture for the development of real-time fault diagnosis systems using model-based reasoning

Presented here is an architecture for implementing real-time telemetry based diagnostic systems using model-based reasoning. First, we describe Paragon, a knowledge acquisition tool for offline entry and validation of physical system models. Paragon provides domain experts with a structured editing capability to capture the physical component's structure, behavior, and causal relationships. We next describe the architecture of the run time diagnostic system. The diagnostic system, written entirely in Ada, uses the behavioral model developed offline by Paragon to simulate expected component states as reflected in the telemetry stream. The diagnostic algorithm traces causal relationships contained within the model to isolate system faults. Since the diagnostic process relies exclusively on the behavioral model and is implemented without the use of heuristic rules, it can be used to isolate unpredicted faults in a wide variety of systems. Finally, we discuss the implementation of a prototype system constructed using this technique for diagnosing faults in a science instrument. The prototype demonstrates the use of model-based reasoning to develop maintainable systems with greater diagnostic capabilities at a lower cost.

Hall, Gardiner A.↗

The Evolution of Dust in the Multiphase Interstellar Medium

Interstellar dust has a profound effect on the structure and evolution of the interstellar medium (ISM) and on the processes by which stars form from it. Dust obscures regions of star formation from view, and the uncertain quantities of elements in dust makes it difficult to measure accurately the abundances of the elements in low density regions. Despite the central importance of dust in astrophysics, we cannot answer some of the most basic questions about it: Why is it that most of the refractory elements are in dust grains? What determines the sizes of interstellar grains? It has been the goal of our proposed theoretical investigations to address these questions by studying the destruction of interstellar grains, and to develop observational diagnostics that can test the models we develop.

Oliversen, Ronald J.↗

A Generic Modeling Process to Support Functional Fault Model Development

Functional fault models (FFMs) are qualitative representations of a system's failure space that are used to provide a diagnostic of the modeled system. An FFM simulates the failure effect propagation paths within a system between failure modes and observation points. These models contain a significant amount of information about the system including the design, operation and off nominal behavior. The development and verification of the models can be costly in both time and resources. In addition, models depicting similar components can be distinct, both in appearance and function, when created individually, because there are numerous ways of representing the failure space within each component. Generic application of FFMs has the advantages of software code reuse: reduction of time and resources in both development and verification, and a standard set of component models from which future system models can be generated with common appearance and diagnostic performance. This paper outlines the motivation to develop a generic modeling process for FFMs at the component level and the effort to implement that process through modeling conventions and a software tool. The implementation of this generic modeling process within a fault isolation demonstration for NASA's Advanced Ground System Maintenance (AGSM) Integrated Health Management (IHM) project is presented and the impact discussed.

Design Analysis↗

Development of an On-board Failure Diagnostics and Prognostics System for Solid Rocket Booster

We develop a case breach model for the on-board fault diagnostics and prognostics system for subscale solid-rocket boosters (SRBs). The model development was motivated by recent ground firing tests, in which a deviation of measured time-traces from the predicted time-series was observed. A modified model takes into account the nozzle ablation, including the effect of roughness of the nozzle surface, the geometry of the fault, and erosion and burning of the walls of the hole in the metal case. The derived low-dimensional performance model (LDPM) of the fault can reproduce the observed time-series data very well. To verify the performance of the LDPM we build a FLUENT model of the case breach fault and demonstrate a good agreement between theoretical predictions based on the analytical solution of the model equations and the results of the FLUENT simulations. We then incorporate the derived LDPM into an inferential Bayesian framework and verify performance of the Bayesian algorithm for the diagnostics and prognostics of the case breach fault. It is shown that the obtained LDPM allows one to track parameters of the SRB during the flight in real time, to diagnose case breach fault, and to predict its values in the future. The application of the method to fault diagnostics and prognostics (FD&P) of other SRB faults modes is discussed.

Smelyanskiy, Vadim N.↗

Hybrid Neural-Network: Genetic Algorithm Technique for Aircraft Engine Performance Diagnostics Developed and Demonstrated

As part of the NASA Aviation Safety Program, a unique model-based diagnostics method that employs neural networks and genetic algorithms for aircraft engine performance diagnostics has been developed and demonstrated at the NASA Glenn Research Center against a nonlinear gas turbine engine model. Neural networks are applied to estimate the internal health condition of the engine, and genetic algorithms are used for sensor fault detection, isolation, and quantification. This hybrid architecture combines the excellent nonlinear estimation capabilities of neural networks with the capability to rank the likelihood of various faults given a specific sensor suite signature. The method requires a significantly smaller data training set than a neural network approach alone does, and it performs the combined engine health monitoring objectives of performance diagnostics and sensor fault detection and isolation in the presence of nominal and degraded engine health conditions.

Kobayashi, Takahisa↗

Rocket engine diagnostics using qualitative modeling techniques

Researchers at NASA Lewis Research Center are presently developing qualitative modeling techniques for automated rocket engine diagnostics. A qualitative model of a turbopump interpropellant seal system was created. The qualitative model describes the effects of seal failures on the system steady state behavior. This model is able to diagnose the failure of particular seals in the system based on anomalous temperature and pressure values. The anomalous values input to the qualitative model are generated using numerical simulations. Diagnostic test cases include both single and multiple seal failures.

Binder, Michael↗

Rocket engine diagnostics using qualitative modeling techniques

Researchers at NASA Lewis Research Center are presently developing qualitative modeling techniques for automated rocket engine diagnostics. A qualitative model of a turbopump interpropellant seal system has been created. The qualitative model describes the effects of seal failures on the system steady-state behavior. This model is able to diagnose the failure of particular seals in the system based on anomalous temperature and pressure values. The anomalous values input to the qualitative model are generated using numerical simulations. Diagnostic test cases include both single and multiple seal failures.

Binder, Michael↗

Demonstrating Assurance of Model-Based Fault Diagnosis Systems on an Operational Mission

Developers of robotic scientific and commercial spacecraft are trending towards use of onboard autonomous capabilities for responding quickly to dynamic environments and rapidly changing situations. These capabilities need to know the state of the spacecraft’s health. Model-based fault diagnosis (MBFD) is an approach to estimating health by continuously verifying accurate behavior and diagnosing off-nominal behavior. Proper functioning of MBFD depends on 1) the quality of the diagnostic system model that is analyzed and compared to commands and onboard measurements to estimate a system’s health state, and 2) the correct functionality of the diagnosis engine interrogating the model and comparing its analyses to observed system behavior. Our goal is to develop Verification and Validation (V&V) techniques for MBFD to provide future missions sufficient confidence in its functionality and performance to deploy it on the systems they develop. Our work has been focused on infusing the techniques we developed earlier to an operational mission. First, we are constructing diagnostic models of a spacecraft attitude control system and updating our diagnostic engine so they can be demonstrated aboard the Arcsecond Space Telescope Enabling Research in Astrophysics (ASTERIA) mission, an operational spacecraft for which experiments in autonomy are being planned and executed, using the V&V techniques we have previously developed to assure they are both correct and complete. Since it is nearing the end of its life, ASTERIA provides a unique opportunity to demonstrate MBFD since the monitored components are expected to fail. Our demonstration will give system developers additional confidence to make timely, informed MBFD deployment decisions. Second, we will be completing performance assessments of the diagnostic engine/diagnostic model ensemble both on the flight system and ground-based testbeds to gain confidence in MBFD’s ability to run successfully in a spacecraft’s resource-constrained environment without adversely affecting other on-board activities. Finally, we are capturing our experience in preparing this demonstration in a set of checklists and guidance documents. Current practice includes high-level institutional guidance documents and standards, but at a high level of abstraction that does not necessarily address specific MBFD concerns. The purpose of the new checklists is to provide future mission developers clear, unambiguous, procedure-oriented guidance on assuring MBFD. This paper describes our work in these areas. For the first area, we describe the diagnostic models and updated diagnostic engine that will be used for the on-board demonstration. We describe how the V&V techniques we developed earlier are used to assure model and engine correctness and completeness. For the second area, we identify the performance measurement and assessment techniques used to characterize the diagnostic engine and diagnostic models, and discuss the effect of measured performance on overall mission operation. Finally, we present the checklist and guidance documents and describe how they meet the goals of providing system developers with clear, unambiguous, procedure-oriented guidance on MBFD assurance. We show how the techniques we have developed map into those artifacts.

Nikora, Allen↗

Qualitative model-based diagnostics for rocket systems

A diagnostic software package is currently being developed at NASA LeRC that utilizes qualitative model-based reasoning techniques. These techniques can provide diagnostic information about the operational condition of the modeled rocket engine system or subsystem. The diagnostic package combines a qualitative model solver with a constraint suspension algorithm. The constraint suspension algorithm directs the solver's operation to provide valuable fault isolation information about the modeled system. A qualitative model of the Space Shuttle Main Engine's oxidizer supply components was generated. A diagnostic application based on this qualitative model was constructed to process four test cases: three numerical simulations and one actual test firing. The diagnostic tool's fault isolation output compared favorably with the input fault condition.

Maul, William↗

Qualitative model-based diagnostics for rocket systems

A diagnostic software package is currently being developed at NASA LeRC that utilizes qualitative model-based reasoning techniques. These techniques can provide diagnostic information about the operational condition of the modeled rocket engine system or subsystem. The diagnostic package combines a qualitative model solver with a constraint suspension algorithm. The constraint suspension algorithm directs the solver's operation to provide valuable fault isolation information about the modeled system. A qualitative model of the Space Shuttle Main Engine's oxidizer supply components was generated. A diagnostic application based on this qualitative model was constructed to process four test cases: three numerical simulations and one actual test firing. The diagnostic tool's fault isolation output compared favorably with the input fault condition.

Maul, William↗

Diagnosis and Prognosis of Weapon Systems

The Prognostics Framework is a set of software tools with an open architecture that affords a capability to integrate various prognostic software mechanisms and to provide information for operational and battlefield decision-making and logistical planning pertaining to weapon systems. The Prognostics NASA Tech Briefs, February 2005 17 Framework is also a system-level health -management software system that (1) receives data from performance- monitoring and built-in-test sensors and from other prognostic software and (2) processes the received data to derive a diagnosis and a prognosis for a weapon system. This software relates the diagnostic and prognostic information to the overall health of the system, to the ability of the system to perform specific missions, and to needed maintenance actions and maintenance resources. In the development of the Prognostics Framework, effort was focused primarily on extending previously developed model-based diagnostic-reasoning software to add prognostic reasoning capabilities, including capabilities to perform statistical analyses and to utilize information pertaining to deterioration of parts, failure modes, time sensitivity of measured values, mission criticality, historical data, and trends in measurement data. As thus extended, the software offers an overall health-monitoring capability.

Nolan, Mary↗

Supersonic Combustion Research at NASA

This paper discusses the progress of work to model high-speed supersonic reacting flow. The purpose of the work is to improve the state of the art of CFD capabilities for predicting the flow in high-speed propulsion systems, particularly combustor flowpaths. The program has several components including the development of advanced algorithms and models for simulating engine flowpaths as well as a fundamental experimental and diagnostic development effort to support the formulation and validation of the mathematical models. The paper will provide details of current work on experiments that will provide data for the modeling efforts along with the associated nonintrusive diagnostics used to collect the data from the experimental flowfield. Simulation of a recent experiment to partially validate the accuracy of a combustion code is also described.

Drummond, J. P.↗