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Failure Modes, Effects, and Criticality Analysis Model disregards failures of insignificant components. Assumptions used to establish baselines for reliability prediction and analytical method are listed. Techniques are applicable to any commercial design and can be extended into software or management systems.
High-temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, Stirling cycle heat sources; and with the resurgence of space nuclear power both as reactor heat removal elements and as radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly, long-term materials compatibility is being evaluated through the use of high-temperature life test heat pipes. Thermacore, Inc., has carried out a sodium heat pipe 10-year life test to establish long-term operating reliability. Sodium heat pipes have demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 87,000 hr (10 years) at nearly 700 C. These life test results have demonstrated the potential for high-temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability. Detailed design specifications, operating history, and post-test analysis of the heat pipe and sodium working fluid are described. Lessons learned and future life test plans are also discussed.
High-temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, Stirling cycle heat sources; and with the resurgence of space nuclear power both as reactor heat removal elements and as radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly, long-term materials compatibility is being evaluated through the use of high-temperature life test heat pipes. Thermacore, Inc., has carried out a sodium heat pipe 10-year life test to establish long-term operating reliability. Sodium heat pipes have demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 87,000 hr (10 yr) at nearly 700 C. These life test results have demonstrated the potential for high-temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability. Detailed design specifications, operating history, and post-test analysis of the heat pipe and sodium working fluid are described.
High temperature heat pipes are being evaluated for use in energy conversion applications such as fuel cells, gas turbine re-combustors, and Stirling cycle heat sources; with the resurgence of space nuclear power, additional applications include reactor heat removal elements and radiator elements. Long operating life and reliable performance are critical requirements for these applications. Accordingly long-term materials compatibility is being evaluated through the use of high temperature life test heat pipes. Thermacore International, Inc., has carried out several sodium heat pipe life tests to establish long term operating reliability. Four sodium heat pipes have recently demonstrated favorable materials compatibility and heat transport characteristics at high operating temperatures in air over long time periods. A 3l6L stainless steel heat pipe with a sintered porous nickel wick structure and an integral brazed cartridge heater has successfully operated at 650 to 700 C for over 115,000 hours without signs of failure. A second 3l6L stainless steel heat pipe with a specially-designed Inconel 60 I rupture disk and a sintered nickel powder wick has demonstrated over 83,000 hours at 600 to 650 C with similar success. A representative one-tenth segment Stirling Space Power Converter heat pipe with an Inconel 718 envelope and a stainless steel screen wick has operated for over 41 ,000 hours at nearly 700 0c. A hybrid (i.e. gas-fired and solar) heat pipe with a Haynes 230 envelope and a sintered porous nickel wick structure was operated for about 20,000 hours at nearly 700 C without signs of degradation. These life test results collectively have demonstrated the potential for high temperature heat pipes to serve as reliable energy conversion system components for power applications that require long operating lifetime with high reliability, Detailed design specifications, operating hi story, and test results are described for each of these sodium heat pipes. Lessons learned and future life test plans are also discussed.
Carbon dioxide (CO2) removal technology development for portable life support systems (PLSS) has traditionally concentrated in the areas of solid and liquid chemical sorbents and semi-permeable membranes. Most of these systems are too heavy in gravity environments, require prohibitive amounts of consumables for operation on long term planetary missions, or are inoperable on the surface of Mars due to the presence of a CO2 atmosphere. This paper describes the effort performed to mature an innovative CO2 removal technology that meets NASA s planetary mission needs while adhering to the important guiding principles of simplicity, reliability, and operability. A breadboard cryogenic carbon dioxide scrubber (Cryo Scrubber) for a closed loop cryogenic PLSS was developed, designed, and tested, and a conceptual design suitable for a PLSS was developed based on the results of the breadboard testing. The Cryo Scrubber freezes CO2 and other trace contaminants out of expired vent loop gas using cooling available from a liquid oxygen (LOX) based PLSS. The device is continuously regenerable, with solid CO2 being removed from the cold freeze-out surfaces, sublimated, and vented overboard. Duration is limited only by the supply of LOX stored in the PLSS. Simplicity, reliability, and operability are universally important criteria for critical hardware on long duration Lunar or Mars missions. The Cryo Scrubber has no moving parts, requires no additional consumables, and uses no electrical power, contributing to its simplicity and reliability. It is easy to use; no operator action is required to prepare, use, or shut down the Cryo Scrubber, and it does not require charging or regeneration. The versatility of the concept allows for operation on earth, the moon, and Mars, and in microgravity.
Ground system design approach integrating reliability and maintainability with performance requirements, using Saturn V simulation as example
Reliability and lifetime of quasi-CW laser diode arrays are greatly influenced by their thermal characteristics. This paper examines the thermal properties of laser diode arrays operating in long pulse duration regime.
The premise to be tested in this analysis is whether cost economics may accrue by delivering more landers designed to lower reliability of operation (compared to fewer landers of higher reliability) to obtain a desired probability of achieving a given number of lander successes. Generally, the application in mind is a network of penetrators, although the analysis may apply as well to other small lander concepts or even to simple rovers. The method of analysis is based on a probabilistic model of lander success and a related probabilistic model of project cost including the lander, spacecraft carrier, and integration, but not launch or operations costs. Quantitative results are obtained in a normalized and parametric fashion. Sensitivity to the assumed model parameters is also examined.
This viewgraph presentation reviews the workings of the Laser Diode Arrays (LDA) working group. The group facilitates focused interaction between the LDA user and provider communities and it will author standards document for the specification and qualification of LDA's for operation in the space environment. It also reviews the NASA test and evaluation facilities that are available to the community.
The successful launch of a space shuttle vehicle depends on the proper operation of two tail service masts (TSMs). Reliable TSM operation is assured through a comprehensive design, development, and testing program. The results of the concept verification test (CVT) and the resulting impact on prototype TSM design are presented. The design criteria are outlined, and the proposed prototype TSM tests are described.
A technology development program was conducted to evolve an earlier metallic thermal protection system (TPS) panel design, with the goals of: improving operations features, increasing adaptability (ease of attaching to a variety of tank shapes and structural concepts), and reducing weight. The resulting Adaptable Robust Metallic Operable Reusable (ARMOR) TPS system incorporates a high degree of design flexibility (allowing weight and operability to be traded and balanced) and can also be easily integrated with a large variety of tank shapes, airframe structural arrangements and airframe structure/material concepts. An initial attempt has been made to establish a set of performance based TPS design requirements. A set of general (FARtype) requirements have been proposed, focusing on defining categories that must be included for a comprehensive design. Load cases required for TPS design must reflect the full flight envelope, including a comprehensive set of limit loads, However, including additional loads. such as ascent abort trajectories, as ultimate load cases, and on-orbit debris/micro-meteoroid hypervelocity impact, as one of the discrete -source -damage load cases, will have a significant impact on system design and resulting performance, reliability and operability. Although these load cases have not been established, they are of paramount importance for reusable vehicles, and until properly included, all sizing results and assessments of reliability and operability must be considered optimistic at a minimum.
This document summarizes and updates the NESC Guidance, Navigation, and Control (GN&C) Technical Discipline Team’s (TDT) work to synthesize and document the current best practices for the design & development of robust and reliable GN&C systems for robotic and crewed (human-rated) spacecraft. These GN&C best practices for future science and exploration missions were derived from the lessons learned, both positive and negative, on earlier spaceflight projects, both robotic and crewed. An attempt has been made to capture preferred practices that reflect the key considerations, trades, and processes directly attributed to past mission success.
This paper is to address the in-flight reliability of a liquid propulsion engine system for a launch vehicle. We first establish a comprehensive list of system and sub-system reliability drivers for any liquid propulsion engine system. We then build a reliability model to parametrically analyze the impact of some reliability parameters. We present sensitivity analysis results for a selected subset of the key reliability drivers using the model. Reliability drivers identified include: number of engines for the liquid propulsion stage, single engine total reliability, engine operation duration, engine thrust size, reusability, engine de-rating or up-rating, engine-out design (including engine-out switching reliability, catastrophic fraction, preventable failure fraction, unnecessary shutdown fraction), propellant specific hazards, engine start and cutoff transient hazards, engine combustion cycles, vehicle and engine interface and interaction hazards, engine health management system, engine modification, engine ground start hold down with launch commit criteria, engine altitude start (1 in. start), Multiple altitude restart (less than 1 restart), component, subsystem and system design, manufacturing/ground operation support/pre and post flight check outs and inspection, extensiveness of the development program. We present some sensitivity analysis results for the following subset of the drivers: number of engines for the propulsion stage, single engine total reliability, engine operation duration, engine de-rating or up-rating requirements, engine-out design, catastrophic fraction, preventable failure fraction, unnecessary shutdown fraction, and engine health management system implementation (basic redlines and more advanced health management systems).
This reliability study was performed in order to provide the aviation community with an estimate of Complex General Aviation (GA) Aircraft System reliability. To successfully improve the safety and reliability for the next generation of GA aircraft, a study of current GA aircraft attributes was prudent. This was accomplished by benchmarking the reliability of operational Complex GA Aircraft Systems. Specifically, Complex GA Aircraft System reliability was estimated using data obtained from the logbooks of a random sample of the Complex GA Aircraft population.
The results of two experiments examining the effects of shifts in the type and level of automation on operator performance are presented. The first examines the costs and benefits of adaptive-automation shifts on operator performance, while the second experiment examines the effects of variations in automation reliability on operator detection of automation failures. Performance consequences of complacency in system monitoring are shown to be related to characteristics of the monitoring task automation, i.e., automation reliability and consistency.
Designing reliable, low cost, and operable space systems has become the key to future space operations. Designing high quality space systems at low cost is an economic and technological challenge to the designer. A systematic and efficient way to meet this challenge is a new method of design optimization for performance, quality, and cost, called Robust Design. Robust Design is an approach for design optimization. It consists of: making system performance insensitive to material and subsystem variation, thus allowing the use of less costly materials and components; making designs less sensitive to the variations in the operating environment, thus improving reliability and reducing operating costs; and using a new structured development process so that engineering time is used most productively. The objective in Robust Design is to select the best combination of controllable design parameters so that the system is most robust to uncontrollable noise factors. The robust design methodology uses a mathematical tool called an orthogonal array, from design of experiments theory, to study a large number of decision variables with a significantly small number of experiments. Robust design also uses a statistical measure of performance, called a signal-to-noise ratio, from electrical control theory, to evaluate the level of performance and the effect of noise factors. The purpose is to investigate the Robust Design methodology for improving quality and cost, demonstrate its application by the use of an example, and suggest its use as an integral part of space system design process.
Accurate analysis of reliability of system requires that it accounts for all major variations in system's operation. Most reliability analyses assume that the system configuration, success criteria, and component behavior remain the same. However, multiple phases are natural. We present a new computationally efficient technique for analysis of phased-mission systems where the operational states of a system can be described by combinations of components states (such as fault trees or assertions). Moreover, individual components may be repaired, if failed, as part of system operation but repairs are independent of the system state. For repairable systems Markov analysis techniques are used but they suffer from state space explosion. That limits the size of system that can be analyzed and it is expensive in computation. We avoid the state space explosion. The phase algebra is used to account for the effects of variable configurations, repairs, and success criteria from phase to phase. Our technique yields exact (as opposed to approximate) results. We demonstrate our technique by means of several examples and present numerical results to show the effects of phases and repairs on the system reliability/availability.
The characterization of 8300 A lasers was broadened, especially in the area of beam quality. Modulation rates up to 2 Gbit/sec at output powers of 20 mW were observed, waveform fidelity was fully adequate for low BER data transmission, and wavefront measurements showed that phase aberrations were less than lamda/50. Also, individually addressable arrays of up to ten contiguous diode lasers were fabricated and tested. Each laser operates at powers up to 30 mW CW in single spatial mode. Shifting the operating wavelength of the basic CSP laser from 8300 A to 8650 A was accomplished by the addition of Si to the active region. Output power has reached 100 mW single mode, with excellent far field wave front properties. Operating life is currently approx. 1000 hrs at 35 mW CW. In addition, laser reliability, for operation at both 8300 A and 8650 A, has profited significantly from several developments in the processing procedures.