Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “hardware failure”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 505 records · Page 28

Post-Shuttle EVA Operations on ISS

The EVA hardware used to assemble and maintain the ISS was designed with the assumption that it would be returned to Earth on the Space Shuttle for ground processing, refurbishment, or failure investigation (if necessary). With the retirement of the Space Shuttle, a new concept of operations was developed to enable EVA hardware (EMU, Airlock Systems, EVA tools, and associated support equipment and consumables) to perform ISS EVAs until 2016 and possibly beyond to 2020. Shortly after the decision to retire the Space Shuttle was announced, NASA and the One EVA contractor team jointly initiated the EVA 2010 Project. Challenges were addressed to extend the operating life and certification of EVA hardware, secure the capability to launch EVA hardware safely on alternate launch vehicles, and protect EMU hardware operability on orbit for long durations.

West, Bill↗

Optimization of Second Fault Detection Thresholds to Maximize Mission POS

In order to support manned spaceflight safety requirements, the Space Launch System (SLS) has defined program-level requirements for key systems to ensure successful operation under single fault conditions. To accommodate this with regards to Navigation, the SLS utilizes an internally redundant Inertial Navigation System (INS) with built-in capability to detect, isolate, and recover from first failure conditions and still maintain adherence to performance requirements. The unit utilizes multiple hardware- and software-level techniques to enable detection, isolation, and recovery from these events in terms of its built-in Fault Detection, Isolation, and Recovery (FDIR) algorithms. Successful operation is defined in terms of sufficient navigation accuracy at insertion while operating under worst case single sensor outages (gyroscope and accelerometer faults at launch). In addition to first fault detection and recovery, the SLS program has also levied requirements relating to the capability of the INS to detect a second fault, tracking any unacceptable uncertainty in knowledge of the vehicle's state. This detection functionality is required in order to feed abort analysis and ensure crew safety. Increases in navigation state error and sensor faults can drive the vehicle outside of its operational as-designed environments and outside of its performance envelope causing loss of mission, or worse, loss of crew. The criteria for operation under second faults allows for a larger set of achievable missions in terms of potential fault conditions, due to the INS operating at the edge of its capability. As this performance is defined and controlled at the vehicle level, it allows for the use of system level margins to increase probability of mission success on the operational edges of the design space. Due to the implications of the vehicle response to abort conditions (such as a potentially failed INS), it is important to consider a wide range of failure scenarios in terms of both magnitude and time. As such, the Navigation team is taking advantage of the INS's capability to schedule and change fault detection thresholds in flight. These values are optimized along a nominal trajectory in order to maximize probability of mission success, and reducing the probability of false positives (defined as when the INS would report a second fault condition resulting in loss of mission, but the vehicle would still meet insertion requirements within system-level margins). This paper will describe an optimization approach using Genetic Algorithms to tune the threshold parameters to maximize vehicle resilience to second fault events as a function of potential fault magnitude and time of fault over an ascent mission profile. The analysis approach, and performance assessment of the results will be presented to demonstrate the applicability of this process to second fault detection to maximize mission probability of success.

Anzalone, Evan↗

Long life assurance study for manned spacecraft long life hardware. Volume 1: Summary of long life assurance guidelines

A long life assurance program for the development of design, process, test, and application guidelines for achieving reliable spacecraft hardware was conducted. The study approach consisted of a review of technical data performed concurrently with a survey of the aerospace industry. The data reviewed included design and operating characteristics, failure histories and solutions, and similar documents. The topics covered by the guidelines are reported. It is concluded that long life hardware is achieved through meticulous attention to many details and no simple set of rules can suffice.

Source record↗

Reversionary Control Modes for the Mitigation of Failures in a Partially Turboelectric Aircraft Propulsion System

In support of emission and fuel burn reduction goals, the aviation industry is actively pursuing the advancement of electrified aircraft propulsion (EAP) technology. This includes turboelectric and hybrid electric propulsion designs that combine gas turbine engine and electrical system hardware. Such architectures exhibit a high degree of coupling between subsystems. This drives the need for system-level control strategies to ensure the safe, coordinated, and efficient operation of all subsystems. The design and certification of any aircraft propulsion system requires that all potential subsystem failures are identified, and the hazards posed by these failures are appropriately mitigated. This requirement is particularly challenging for EAP systems due to their integrated nature. One approach to assist in EAP failure mitigation is the inclusion of automated reconfiguration capabilities within the propulsion control system. Such control modes, referred to as reversionary control modes, are designed to automatically detect failures and activate backup control modes upon failure detection. This paper covers the design and evaluation of reversionary control mode logic developed for a partially turboelectric propulsion concept. Test results from a real-time hardware-in-the-loop evaluation of the concept are also presented and discussed. The results show that the developed reversionary control logic can successfully detect and mitigate subsystem failures in a representative environment that includes actual electrical system hardware.

Electrified Aircraft Propulsion↗

Reversionary Control Modes for the Mitigation of Failures in a Partially Turboelectric Aircraft Propulsion System

In support of emission and fuel burn reduction goals, the aviation industry is actively pursuing the advancement of electrified aircraft propulsion (EAP) technology. This includes turboelectric and hybrid electric propulsion designs that combine gas turbine engine and electrical system hardware. Such architectures exhibit a high degree of coupling between subsystems. This drives the need for system-level control strategies to ensure the safe, coordinated, and efficient operation of all subsystems. The design and certification of any aircraft propulsion system requires that all potential subsystem failures are identified, and the hazards posed by these failures are appropriately mitigated. This requirement is particularly challenging for EAP systems due to their integrated nature. One approach to assist in EAP failure mitigation is the inclusion of automated reconfiguration capabilities within the propulsion control system. Such control modes, referred to as reversionary control modes, are designed to automatically detect failures and activate backup control modes upon failure detection. This paper covers the design and evaluation of reversionary control mode logic developed for a partially turboelectric propulsion concept. Test results from a real-time hardware-in-the-loop evaluation of the concept are also presented and discussed. The results show that the developed reversionary control logic can successfully detect and mitigate subsystem failures in a representative environment that includes actual electrical system hardware.

Electrified Aircraft Propulsion↗

Reversionary Control Modes for the Mitigation of Failures in a Partially Turboelectric Aircraft Propulsion System

In support of emission and fuel burn reduction goals, the aviation industry is actively pursuing the advancement of electrified aircraft propulsion (EAP) technology. This includes turboelectric and hybrid electric propulsion designs that combine gas turbine engine and electrical system hardware. Such architectures exhibit a high degree of coupling between subsystems. This drives the need for system-level control strategies to ensure the safe, coordinated, and efficient operation of all subsystems. The design and certification of any aircraft propulsion system requires that all potential subsystem failures are identified, and the hazards posed by these failures are appropriately mitigated. This requirement is particularly challenging for EAP systems due to their integrated nature. One approach to assist in EAP failure mitigation is the inclusion of automated reconfiguration capabilities within the propulsion control system. Such control modes, referred to as reversionary control modes, are designed to automatically detect failures and activate backup control modes upon failure detection. This paper covers the design and evaluation of reversionary control mode logic developed for a partially turboelectric propulsion concept. Test results from a real-time hardware-in-the-loop evaluation of the concept are also presented and discussed. The results show that the developed reversionary control logic can successfully detect and mitigate subsystem failures in a representative environment that includes actual electrical system hardware.

Electrified Aircraft Propulsion↗

Maximum likelihood failure detection techniques applied to the shuttle orbiter reaction control subsystem

A technique for on-board detection and identification of hard failures and leaks of the shuttle orbiter reaction control subsystem jets, during the orbital flight phase, is presented. The method uses gimbal angle and linear accelerometer measurements from the orbiter inertial measurement unit and requires no additional hardware. Extended Kalman filters with residual traps are employed for state estimation, and generalized likelihood ratio tests for jet failure identification. Rigid body simulation results indicate identification times of less than 2 seconds for hard jet failures and less than 70 seconds for jet leaks.

Deckert, J. C.↗

Branch recovery with compiler-assisted multiple instruction retry

In processing systems where rapid recovery from transient faults is important, schemes for multiple instruction rollback recovery may be appropriate. Multiple instruction retry has been implemented in hardware by researchers and also in mainframe computers. This paper extends compiler-assisted instruction retry to a broad class of code execution failures. Five benchmarks were used to measure the performance penalty of hazard resolution. Results indicate that the enhanced pure software approach can produce performance penalties consistent with existing hardware techniques. A combined compiler/hardware resolution strategy is also described and evaluated. Experimental results indicate a lower performance penalty than with either a totally hardware or totally software approach.

Alewine, N. J.↗

Learning from Space Entrepreneurs

The early days of rocketry and space exploration in the United States were marked by incredibly rapid progress: a seemingly endless parade of firsts. Not coincidentally, this period also saw more than its fair share of failure, especially in the infamous "kaputnik" days prior to the successful launch of Explorer. Without a standard canon of known quantities to turn to, the early pioneers of rocketry and space flight were forced to dream up new ideas that ranged from the elegant to the bizarre and to accept the fact that the price of radical progress is occasional failure. Nowadays, rapid prototyping and testing have slowed, as we rely more and more on the extensive knowledge pined by our predecessors and on the embarrassment of riches modern engineers get from computational modeling and computer assisted design. In many cases, this leads to much improved or phenomenally more efficient designs. It also, however, fosters a culture so terrified of failure that we over-engineer and overanalyze everything, often tweaking designs for decades before a new system takes flight. (This is not a problem unique to rockets; the same phenomenon seems to have occurred in high-performance jets.) This is one reason why it was possible for President Kennedy to dream of the completion of the Mercury and Gemini missions and a successful landing on the moon in under a decade, while returning to the moon may take nearly twice as long. Lacking access to the tremendous computational resources of the national space program-and, just as importantly, removed from the harsh judgment of public shareholders or congressional appropriations committees-the hungry entrepreneurs who compete for our prizes tend not to display such fear of failure. Instead, most of them follow a rapid "build, test, fly" program. They are willing to throw a handful of concepts against the wall and see what sticks. They often go from drawing on the back of a napkin to firing engines or even flying vehicles in a matter of weeks or months, learning valuable lessons along the way. Indeed, our teams have repeatedly learned many of the most valuable lessons after only a few moments of working with real hardware-lessons that could never have been learned from a CAD drawing, like finding the failure modes of different welding practices or tracking down the interference between an onboard camera and a GPS unit. As Paul Breed, the leader of a Northrop Grumman Lunar Lander Challenge team (playfully called Unreasonable Rocket), is fond of saying, "In computer simulations the plumbing never leaks. In real life, it always does."

Pomerantz, William↗

Static stability of the Space Station solar array FASTMast structure

The combined loads test of the 3-Bay FASTMast marks the end of the Lewis Research Center (LeRC) effort to characterize the behavior of the principal Space Station solar array support structure. The primary objective of this test and analysis effort was to develop a method to predict structural stability failure modes under flight-like applied loads. Included at the beginning of this report is a brief historical perspective of the hardware design development and FASTMast structural stability problem evolution. Once an understanding of the solution process has been established, test and analysis details are presented and related to the postulated failure theories. The combined load test series subjected the structure to a combination of transverse, moment, and torsion loads similar to that expected in the service environment. Nonlinear finite element (FE) models were developed and large displacement analyses were performed to support the test effort and failure mode predictions. Details of the test configuration as well as test and analysis results are presented. The results were then critiqued to establish valid and successful support of the failure mode assessments. Finally, study conclusions are drawn and recommendations for safe operation of the FASTMast structure are presented for consideration.

Shaker, John F.↗

Hypersonic Inflatable Aerodynamic Decelerator (HIAD) Technology Development Overview

The successful flight of the Inflatable Reentry Vehicle Experiment (IRVE)-3 has further demonstrated the potential value of Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology. This technology development effort is funded by NASA's Space Technology Mission Directorate (STMD) Game Changing Development Program (GCDP). This paper provides an overview of a multi-year HIAD technology development effort, detailing the projects completed to date and the additional testing planned for the future. The effort was divided into three areas: Flexible Systems Development (FSD), Mission Advanced Entry Concepts (AEC), and Flight Validation. FSD consists of a Flexible Thermal Protection Systems (FTPS) element, which is investigating high temperature materials, coatings, and additives for use in the bladder, insulator, and heat shield layers; and an Inflatable Structures (IS) element which includes manufacture and testing (laboratory and wind tunnel) of inflatable structures and their associated structural elements. AEC consists of the Mission Applications element developing concepts (including payload interfaces) for missions at multiple destinations for the purpose of demonstrating the benefits and need for the HIAD technology as well as the Next Generation Subsystems element. Ground test development has been pursued in parallel with the Flight Validation IRVE-3 flight test. A larger scale (6m diameter) HIAD inflatable structure was constructed and aerodynamically tested in the National Full-scale Aerodynamics Complex (NFAC) 40ft by 80ft test section along with a duplicate of the IRVE-3 3m article. Both the 6m and 3m articles were tested with instrumented aerodynamic covers which incorporated an array of pressure taps to capture surface pressure distribution to validate Computational Fluid Dynamics (CFD) model predictions of surface pressure distribution. The 3m article also had a duplicate IRVE-3 Thermal Protection System (TPS) to test in addition to testing with the Aerocover configuration. Both the Aerocovers and the TPS were populated with high contrast targets so that photogrammetric solutions of the loaded surface could be created. These solutions both refined the aerodynamic shape for CFD modeling and provided a deformed shape to validate structural Finite Element Analysis (FEA) models. Extensive aerothermal testing has been performed on the TPS candidates. This testing has been conducted in several facilities across the country. The majority of the testing has been conducted in the Boeing Large Core Arc Tunnel (LCAT). HIAD is continuing to mature testing methodology in this facility and is developing new test sample fixtures and control methodologies to improve understanding and quality of the environments to which the samples are subjected. Additional testing has been and continues to be performed in the NASA LaRC 8ft High Temperature Tunnel, where samples up to 2ft by 2ft are being tested over representative underlying structures incorporating construction features such as sewn seams and through-thickness quilting. With the successful completion to the IRVE-3 flight demonstration, mission planning efforts are ramping up on the development of the HIAD Earth Atmospheric Reenty Test (HEART) which will demonstrate a relevant scale vehicle in relevant environments via a large-scale aeroshell (approximately 8.5m) entering at orbital velocity (approximately 7km/sec) with an entry mass on the order of 4MT. Also, the Build to Print (BTP) hardware built as a risk mitigation for the IRVE-3 project to have a "spare" ready to go in the event of a launch vehicle delivery failure is now available for an additional sub-orbital flight experiment. Mission planning is underway to define a mission that can utilize this existing hardware and help the HIAD project further mature this technology.

Hughes, Stephen J.↗

Scattering phase shift in quantum mechanics on quantum computers

Here, we investigate the feasibility of extracting infinite volume scattering phase shift on quantum computers in a simple one-dimensional quantum mechanical model, using the formalism established in the work by Guo and Gasparian [Phys. Rev. D 108, 074504 (2023)] that relates the integrated correlation functions for a trapped system to the infinite volume scattering phase shifts through a weighted integral. The system is first discretized in a finite box with periodic boundary conditions, and the formalism in real time is verified by employing a contact interaction potential with exact solutions. Quantum circuits are then designed and constructed to implement the formalism on current quantum computing architectures. To overcome the fast oscillatory behavior of the integrated correlation functions in real-time simulation, different methods of postdata analysis are proposed and discussed. Test results on IBM hardware show that good agreement can be achieved with two qubits, but complete failure ensues with three qubits due to two-qubit gate operation errors and thermal relaxation errors.

Guo, Peng [Dakota State Univ., Madison, SD (United↗

Analysis of Full-Test tools and their limitations as applied to terminal junction blocks

Discovery of unlocked contacts in Deutsch Block terminal junctions in Solid Rocket Booster flight hardware prompted an investigation into pull test techniques to help insure against possible failures. Internal frictional forces between socket and pin and between wire and grommet were examined. Pull test force must be greater than internal friction yet less than the crimp strength of the pin or socket. For this reason, a 100 percent accurate test is impossible. Test tools were evaluated. Available tools are adequate for pull testing.

Smith, J. L.↗

ALS rocket engine combustion devices design and demonstration

Work performed during Phase one is summarized and the significant technical and programmatic accomplishments occurring during this period are documented. Besides a summary of the results, methodologies, trade studies, design, fabrication, and hardware conditions; the following are included: the evolving Maintainability Plan, Reliability Program Plan, Failure Summary and Analysis Report, and the Failure Mode and Effect Analysis.

Arreguin, Steve↗

Real-Time Simulation for Verification and Validation of Diagnostic and Prognostic Algorithms

To verify that a health management system (HMS) performs as expected, a virtual system simulation capability, including interaction with the associated platform or vehicle, very likely will need to be developed. The rationale for developing this capability is discussed and includes the limited capability to seed faults into the actual target system due to the risk of potential damage to high value hardware. The capability envisioned would accurately reproduce the propagation of a fault or failure as observed by sensors located at strategic locations on and around the target system and would also accurately reproduce the control system and vehicle response. In this way, HMS operation can be exercised over a broad range of conditions to verify that it meets requirements for accurate, timely response to actual faults with adequate margin against false and missed detections. An overview is also presented of a real-time rocket propulsion health management system laboratory which is available for future rocket engine programs. The health management elements and approaches of this lab are directly applicable for future space systems. In this paper the various components are discussed and the general fault detection, diagnosis, isolation and the response (FDIR) concept is presented. Additionally, the complexities of V&V (Verification and Validation) for advanced algorithms and the simulation capabilities required to meet the changing state-of-the-art in HMS are discussed.

Aguilar, Robet↗

Adaptive Inner-Loop Rover Control

Adaptive control technology is developed for the inner-loop speed and steering control of the MAX Rover. MAX, a CMU developed rover, is a compact low-cost 4-wheel drive, 4-wheel steer (double Ackerman), high-clearance agile durable chassis, outfitted with sensors and electronics that make it ideally suited for supporting research relevant to intelligent teleoperation and as a low-cost autonomous robotic test bed and appliance. The design consists of a feedback linearization based controller with a proportional - integral (PI) feedback that is augmented by an online adaptive neural network. The adaptation law has guaranteed stability properties for safe operation. The control design is retrofit in nature so that it fits inside the outer-loop path planning algorithms. Successful hardware implementation of the controller is illustrated for several scenarios consisting of actuator failures and modeling errors in the nominal design.

Kulkarni, Nilesh↗

Space Shuttle Abort Evolution

This paper documents some of the evolutionary steps in developing a rigorous Space Shuttle launch abort capability. The paper addresses the abort strategy during the design and development and how it evolved during Shuttle flight operations. The Space Shuttle Program made numerous adjustments in both the flight hardware and software as the knowledge of the actual flight environment grew. When failures occurred, corrections and improvements were made to avoid a reoccurrence and to provide added capability for crew survival. Finally some lessons learned are summarized for future human launch vehicle designers to consider.

Henderson, Edward M.↗

Supportability Technologies for Future Exploration Missions

Future long-duration human exploration missions will be challenged by resupply limitations and mass and volume constraints. Consequently, it will be essential that the logistics footprint required to support these missions be minimized and that capabilities be provided to make them highly autonomous from a logistics perspective. Strategies to achieve these objectives include broad implementation of commonality and standardization at all hardware levels and across all systems, repair of failed hardware at the lowest possible hardware level, and manufacture of structural and mechanical replacement components as needed. Repair at the lowest hardware levels will require the availability of compact, portable systems for diagnosis of failures in electronic systems and verification of system functionality following repair. Rework systems will be required that enable the removal and replacement of microelectronic components with minimal human intervention to minimize skill requirements and training demand for crews. Materials used in the assembly of electronic systems (e.g. solders, fluxes, conformal coatings) must be compatible with the available repair methods and the spacecraft environment. Manufacturing of replacement parts for structural and mechanical applications will require additive manufacturing systems that can generate near-net-shape parts from the range of engineering alloys employed in the spacecraft structure and in the parts utilized in other surface systems. These additive manufacturing processes will need to be supported by real-time non-destructive evaluation during layer-additive processing for on-the-fly quality control. This will provide capabilities for quality control and may serve as an input for closed-loop process control. Additionally, non-destructive methods should be available for material property determination. These nondestructive evaluation processes should be incorporated with the additive manufacturing process - providing an in-process capability to ensure that material deposited during layer-additive processing meets required material property criteria.

Watson, Kevin↗