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NASA NTRS2005

Engineering Lessons Learned and Systems Engineering Applications

Systems Engineering is fundamental to good engineering, which in turn depends on the integration and application of engineering lessons learned. Thus, good Systems Engineering also depends on systems engineering lessons learned from within the aerospace industry being documented and applied. About ten percent of the engineering lessons learned documented in the NASA Lessons Learned Information System are directly related to Systems Engineering. A key issue associated with lessons learned datasets is the communication and incorporation of this information into engineering processes. As part of the NASA Technical Standards Program activities, engineering lessons learned datasets have been identified from a number of sources. These are being searched and screened for those having a relation to Technical Standards. This paper will address some of these Systems Engineering Lessons Learned and how they are being related to Technical Standards within the NASA Technical Standards Program, including linking to the Agency's Interactive Engineering Discipline Training Courses and the life cycle for a flight vehicle development program.

Gill, Paul S.↗

NASA NTRS2007

Self-Regulating Water-Separator System for Fuel Cells

proposed system would perform multiple coordinated functions in regulating the pressure of the oxidant gas (usually, pure oxygen) flowing to a fuelcell stack and in removing excess product water that is generated in the normal fuel-cell operation. The system could function in the presence or absence of gravitation, and in any orientation in a gravitational field. Unlike some prior systems for removing product water, the proposed system would not depend on hydrophobicity or hydrophilicity of surfaces that are subject to fouling and, consequently, to gradual deterioration in performance. Also unlike some prior systems, the proposed system would not include actively controlled electric motors for pumping; instead, motive power for separation and pumping away of product water would be derived primarily from the oxidant flow and perhaps secondarily from the fuel flow. The net effect of these and other features would be to make the proposed system more reliable and safer, relative to the prior systems. The proposed system (see figure) would include a pressure regulator and sensor in the oxidant supply just upstream from an ejector reactant pump. The pressure of the oxidant supply would depend on the consumption flow. In one of two control subsystems, the pressure of oxidant flowing from the supply to the ejector would be sensed and used to control the speed of a set of a reciprocating constant-displacement pump so that the volumetric flow of nominally incompressible water away from the system would slightly exceed the rate at which water was produced by the fuel cell(s). The two-phase (gas/liquid water) outlet stream from the fuel cell(s) would enter the water separator, a turbinelike centrifugal separator machine driven primarily by the oxidant gas stream. A second control subsystem would utilize feedback derived from the compressibility of the outlet stream: As the separator was emptied of liquid water, the compressibility of the pumped stream would increase. The compressibility would be sensed, and an increase in compressibility beyond a preset point (signifying a decrease in water content below an optimum low level) would cause the outflow from the reciprocating pump to be diverted back to the separator to recycle some water.

Vasquez, Arturo↗

NASA NTRS1980

Development of a trash handling subsystem for a manned spacecraft

A prototype laboratory system to shred and transport trash material within a spacecraft was designed and demonstrated. In addition to handling the normal trash materials, the system demonstrated the ability to handle or reject (if it is too tough) glass, metal and ceramics without damaging the system. The system is not dependent on liquids for the shredding and transportation and can transport slurried, damp or dry material. The resulting system offers a greater system flexibility with operational reliability.

Burnett, M.↗

NASA NTRS1988

A theoretical framework for convergence and continuous dependence of estimates in inverse problems for distributed parameter systems

Numerical techniques for parameter identification in distributed-parameter systems are developed analytically. A general convergence and stability framework (for continuous dependence on observations) is derived for first-order systems on the basis of (1) a weak formulation in terms of sesquilinear forms and (2) the resolvent convergence form of the Trotter-Kato approximation. The extension of this framework to second-order systems is considered.

Banks, H. T.↗

NASA NTRS1992

Coupling plant growth and waste recycling systems in a controlled life support system (CELSS)

The development of bioregenerative systems as part of the Controlled Ecological Life Support System (CELSS) program depends, in large part, on the ability to recycle inorganic nutrients, contained in waste material, into plant growth systems. One significant waste (resource) stream is inedible plant material. This research compared wheat growth in hydroponic solutions based on inorganic salts (modified Hoagland's) with solutions based on the soluble fraction of inedible wheat biomass (leachate). Recycled nutrients in leachate solutions provided the majority of mineral nutrients for plant growth, although additions of inorganic nutrients to leachate solutions were necessary. Results indicate that plant growth and waste recyling systems can be effectively coupled within CELSS based on equivalent wheat yield in leachate and Hoagland solutions, and the rapid mineralization of waste organic material in the hydroponic systems. Selective enrichment for microbial communities able to mineralize organic material within the leachate was necessary to prevent accumulation of dissolved organic matter in leachate-based solutions. Extensive analysis of microbial abundance, growth, and activity in the hydroponic systems indicated that addition of soluble organic material from plants does not cause excessive microbial growth or 'biofouling', and helped define the microbially-mediated flux of carbon in hydroponic solutions.

Garland, Jay L.↗

NASA NTRS1994

Does human cognition allow Human Factors (HF) certification of advanced aircrew systems?

This paper has examined the requirements of HF specification and certification within advanced or complex aircrew systems. It suggests reasons for current inadequacies in the use of HF in the design process, giving some examples in support, and suggesting an avenue towards the improvement of the HF certification process. The importance of human cognition to the operation and performance of advanced aircrew systems has been stressed. Many of the shortfalls of advanced aircrew systems must be attributed to over automated designs that show little consideration on either the mental limits or the cognitive capabilities of the human system component. Traditional approaches to system design and HF certification are set within an over physicalistic foundation. Also, traditionally it was assumed that physicalistic system functions could be attributed to either the human or the machine on a one to one basis. Moreover, any problems associated with the parallel needs, or promoting human understanding alongside system operation and direction, were generally equated in reality by the natural flexibility and adaptability of human skills. The consideration of the human component of a complex system is seen as being primarily based on manifestations of human behavior to the almost total exclusion of any appreciation of unobservable human mental and cognitive processes. The argument of this paper is that the considered functionality of any complex human-machine system must contain functions that are purely human and purely cognitive. Human-machine system reliability ultimately depends on human reliability and dependability and, therefore, on the form and frequency of cognitive processes that have to be conducted to support system performance. The greater the demand placed by an advanced aircraft system on the human component's basic knowledge processes or cognition, rather than on skill, the more insiduous the effects the human may have on that system. This paper discusses one example of an attempt to devise an improved method of specificaiton and certification with relation to the advanced aircrew system, that of the RN Merlin helicopter. The method is realized to have limitations in practice, these mainly associated with the late production of the system specification in relation to the system development process. The need for a careful appreciation of the capabilities and support needs of human cognition within the design process of a complex man machine system has been argued, especially with relation to the concept of system functionality. Unlike the physicalistic Fitts list, a new classification of system functionality is proposed, namely: (1) equipment - system equipment related; (2) cognitive - human cognition related; and (3) associated - necessary combinatin of equipment and cognitive. This paper has not proposed a method for a fuller consideration of cognition within systems design, but has suggested the need for such a method and indicated an avenue towards its development. Finally, the HF certification of advanced aircrew systems is seen as only being possible in a qualified sense until the important functions of human cognition are considered within the system design process. (This paper contains the opinions of its authors and does not necessarily refledt the standpoint of their respective organizations).

Macleod, Iain S.↗

NASA NTRS1995

Fuel Flexible Gas Turbine Combustor Flametube Facility Upgraded

In fiscal year 2003, test cell 23 of the Research Combustion Laboratory (RCL 23) at the NASA Glenn Research Center was upgraded with the addition of gaseous hydrogen as a working propellant and the addition of a 450-psig air-supply system. Test flexibility was further enhanced by upgrades to the facility control systems. RCL 23 can now test with gaseous hydrogen flow rates up to 0.05 lbm/sec and jet fuel flow rates up to 0.62 lbm/sec. Research airflow rates up to 3 lbm/sec are possible with the 450-psig supply system over a range of inlet temperatures. Nonvitiated, heated air is supplied from a shell and tube heat exchanger. The maximum nonvitiated facility air temperature is 1100 F at 1.5 lbm/sec. Research-section exhaust temperatures are limited to 3200 F because of material and cooling capacity limits. A variety of support systems are available depending on the research hardware configuration. Test section ignition can be provided via either a hydrogen air torch system or an electronic spark system. Emissions measurements are obtained with either pneumatically or electromechanically actuated gas sample probes, and the electromechanical system allows for radial measurements at a user-specified axial location for measurement of emissions profiles. Gas analysis data can be obtained for a variety of species, including carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NO and NOx), oxygen (O2), unburnt hydrocarbons, and unburnt hydrogen. Facility control is accomplished with a programmable logic control system. Facility operations have been upgraded to a system based on graphical user interface control screens. A data system is available for real-time acquisition and monitoring of both measurements in engineering units and performance calculations. The upgrades have made RCL 23 a highly flexible facility for research into low emissions gas turbine combustor concepts, and the flame tube configuration inherently allows for a variety of fuel nozzle configurations to be tested in a cost-effective manner. RCL 23 is poised to be a leading facility for developing modern low-emission fuel nozzles for use with jet fuel and alternative fuels.

Little, James E.↗

NASA NTRS1995

Detecting Hidden Failure Modes in Critical, Embedded Software

This experience report describes a method that has been used successfully to detect hidden failure modes in critical, embedded spacecraft software. The method is an adaptation of an earlier, controversial approach called failure modes and effects analysis. The adapted method was found to be well-suited to identifying latent software design weaknesses involving complex system interactions and dependencies in the two applications described here. This experience may be useful for other high-integrity software systems in which the possibility of hidden failure modes is a major concern.

detecting software failure design analysis↗

NASA NTRS1994

3-D Unsteady Flow Visualization in Computational Fluid Dynamics

Presently, there are very few visualization systems available for time-dependent flow fields. Although existing visualization systems for instantaneous flow fields may be used to view time-dependent flow fields at discrete points in time, the time variable is usually not considered in the visualization technique. A simple and effective approach for visualizing time-dependent flow fields using streaklines is presented. Some results from this approach are shown.

Lane, David A.↗

NASA NTRS1975

The relationship between reliability and bonding techniques in hybrid microcircuits

Differential thermal expansion was shown to be responsible for many observed failures in ceramic chip capacitors mounted on alumina substrates. It is shown that the mounting techniques used in bonding the capacitors have a marked effect upon the thermally induced mechanical stress and thus the failure rate. A mathematical analysis was conducted of a composite model of the capacitor-substrate system to predict the magnitude of thermally induced stresses. It was experimentally observed that the stresses in more compliant bonding systems such as soft lead tin and indium solders are significantly lower than those in hard solder and epoxy systems. The marked dependence upon heating and cooling rate was proven to be a determining factor in the prediction of failure solder systems. It was found that the harder or higher melting solders are less susceptible to thermal cycling effects but that they are more likely to fail during initial processing operations. Strain gage techniques were used to determine thermally induced expansion stresses of the capacitors and the alumina substrates. The compliance of the different bonding mediums was determined. From the data obtained, several recommendations are made concerning the optimum bonding system for the achievement of maximum reliability.

Caruso, S. V.↗

NASA NTRS1976

Aerodynamics as a subway design parameter

A parametric sensitivity study has been performed on the system operational energy requirement in order to guide subway design strategy. Aerodynamics can play a dominant or trivial role, depending upon the system characteristics. Optimization of the aerodynamic parameters may not minimize the total operational energy. Isolation of the station box from the tunnel and reduction of the inertial power requirements pay the largest dividends in terms of the operational energy requirement.

Kurtz, D. W.↗

NASA NTRS1980

Optical-communication systems for deep-space applications

The feasibility of using optical communication systems for data telemetry from deep space vehicles to Earth based receivers is evaluated. Performance analysis shows that practical, photon counting optical systems can transmit data reliably at 30 to 40 dB high rates than existing RF systems, or can be used to extend the communication range by 15 to 20 dB. The advantages of pulse-position modulation (PPM) formats are discussed, and photon counting receiver structures designed for PPM decoding are described. The effects of background interference and weather on receiver performance are evaluated. Some consideration is given to tracking and beam pointing operations, since system performance ultimately depends on the accuracy to which these operations can be carried out. An example of a tracking and pointing system utilizing an optical uplink beacon is presented, and it is shown that microradian beam pointing is within the capabilities of state-of-the-art technology. Recommendations for future theoretical studies and component development programs are presented.

Vilnrotter, V. A.↗

NASA NTRS1986

Electrodynamic tethers for energy conversion

Conductive tethers have been proposed as a new method for converting orbital mechanical energy into electrical power for use on-board a satellite (generator mode) or conversely (motor mode) as a method of providing electric propulsion using electrical energy from the satellite. The operating characteristics of such systems are functionally dependent on orbit altitude and inclination. Effects of these relationships are examined to determine acceptable regions of application. To identify system design considerations, a specific set of system performance goals and requirements are selected. The case selected is for a 25 kW auxiliary power system for use on Space Station. Appropriate system design considerations are developed, and the resulting system is described.

Nobles, W.↗

NASA NTRS1996

Working on the Boundaries: Philosophies and Practices of the Design Process

While systems engineering process is a program formal management technique and contractually binding, the design process is the informal practice of achieving the design project requirements throughout all design phases of the systems engineering process. The design process and organization are systems and component dependent. Informal reviews include technical information meetings and concurrent engineering sessions, and formal technical discipline reviews are conducted through the systems engineering process. This paper discusses and references major philosophical principles in the design process, identifies its role in interacting systems and disciplines analyses and integrations, and illustrates the process application in experienced aerostructural designs.

Ryan, R.↗

NASA NTRS2003

Predictive models for moving contact line flows

Modeling flows with moving contact lines poses the formidable challenge that the usual assumptions of Newtonian fluid and no-slip condition give rise to a well-known singularity. This singularity prevents one from satisfying the contact angle condition to compute the shape of the fluid-fluid interface, a crucial calculation without which design parameters such as the pressure drop needed to move an immiscible 2-fluid system through a solid matrix cannot be evaluated. Some progress has been made for low Capillary number spreading flows. Combining experimental measurements of fluid-fluid interfaces very near the moving contact line with an analytical expression for the interface shape, we can determine a parameter that forms a boundary condition for the macroscopic interface shape when Ca much les than l. This parameter, which plays the role of an "apparent" or macroscopic dynamic contact angle, is shown by the theory to depend on the system geometry through the macroscopic length scale. This theoretically established dependence on geometry allows this parameter to be "transferable" from the geometry of the measurement to any other geometry involving the same material system. Unfortunately this prediction of the theory cannot be tested on Earth.

Rame, Enrique↗

NASA NTRS1995

A method for diagnosing time dependent faults using model-based reasoning systems

This paper explores techniques to apply model-based reasoning to equipment and systems which exhibit dynamic behavior (that which changes as a function of time). The model-based system of interest is KATE-C (Knowledge based Autonomous Test Engineer) which is a C++ based system designed to perform monitoring and diagnosis of Space Shuttle electro-mechanical systems. Methods of model-based monitoring and diagnosis are well known and have been thoroughly explored by others. A short example is given which illustrates the principle of model-based reasoning and reveals some limitations of static, non-time-dependent simulation. This example is then extended to demonstrate representation of time-dependent behavior and testing of fault hypotheses in that environment.

Goodrich, Charles H.↗

NASA NTRS2009

System Synchronizes Recordings from Separated Video Cameras

A system of electronic hardware and software for synchronizing recordings from multiple, physically separated video cameras is being developed, primarily for use in multiple-look-angle video production. The system, the time code used in the system, and the underlying method of synchronization upon which the design of the system is based are denoted generally by the term "Geo-TimeCode(TradeMark)." The system is embodied mostly in compact, lightweight, portable units (see figure) denoted video time-code units (VTUs) - one VTU for each video camera. The system is scalable in that any number of camera recordings can be synchronized. The estimated retail price per unit would be about $350 (in 2006 dollars). The need for this or another synchronization system external to video cameras arises because most video cameras do not include internal means for maintaining synchronization with other video cameras. Unlike prior video-camera-synchronization systems, this system does not depend on continuous cable or radio links between cameras (however, it does depend on occasional cable links lasting a few seconds). Also, whereas the time codes used in prior video-camera-synchronization systems typically repeat after 24 hours, the time code used in this system does not repeat for slightly more than 136 years; hence, this system is much better suited for long-term deployment of multiple cameras.

Nail, William↗