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The results of an analysis performed on seven successive Space Shuttle Main Engine (SSME) static test firings, utilizing envelope detection of external accelerometer data are discussed. The results clearly show the great potential for using envelope detection techniques in SSME incipient failure detection.
This task specified developing the hardware and software necessary to implement the System for Anomaly and Failure Detection (SAFD) algorithm, developed under Technology Test Bed (TTB) Task 21, on the TTB engine stand. This effort involved building two units; one unit to be installed in the Block II Space Shuttle Main Engine (SSME) Hardware Simulation Lab (HSL) at Marshall Space Flight Center (MSFC), and one unit to be installed at the TTB engine stand. Rocketdyne personnel from the HSL performed the task. The SAFD algorithm was developed as an improvement over the current redline system used in the Space Shuttle Main Engine Controller (SSMEC). Simulation tests and execution against previous hot fire tests demonstrated that the SAFD algorithm can detect engine failure as much as tens of seconds before the redline system recognized the failure. Although the current algorithm only operates during steady state conditions (engine not throttling), work is underway to expand the algorithm to work during transient condition.
The performance of the orthogonal series generalized likelihood ratio (OSGLR) test in detecting and isolating commercial aircraft control surface and actuator failures is evaluated. A modification to incorporate age-weighting which significantly reduces the sensitivity of the algorithm to modeling errors is presented. The steady-state implementation of the algorithm based on a single linear model valid for a cruise flight condition is tested using a nonlinear aircraft simulation. A number of off-nominal no-failure flight conditions including maneuvers, nonzero flap deflections, different turbulence levels and steady winds were tested. Based on the no-failure decision functions produced by off-nominal flight conditions, the failure detection and isolation performance at the nominal flight condition was determined. The extension of the algorithm to a wider flight envelope by scheduling on dynamic pressure and flap deflection is examined. Based on this testing, the OSGLR algorithm should be capable of detecting control surface failures that would affect the safe operation of a commercial aircraft. Isolation may be difficult if there are several surfaces which produce similar effects on the aircraft. Extending the algorithm over the entire operating envelope of a commercial aircraft appears feasible.
A new method of sensor failure detection, isolation, and accommodation is described using a neural network approach. In a propulsion system such as the Space Shuttle Main Engine, the dynamics are usually much higher than the order of the system. This built-in redundancy of the sensors can be utilized to detect and correct sensor failure problems. The goal of the proposed scheme is to train a neural network to identify the sensor whose measurement is not consistent with other sensor outputs. Another neural network is trained to recover the value of critical variables when their measurements fail. Techniques for training the network with a limited amount of data are developed. The proposed scheme is tested using the simulated data of the Space Shuttle Main Engine (SSME) inflight sensor group.
A procedure for sensor/actuator failure detection using a generalized likelihood ratio (GLR) test is described. The GLR concept can provide a reliable evaluation of failure occurence when associated with a feedback control design which does not require sensor outputs to provide data estimates. A GLR detector was developed and tested.
A new approach to structural failure detection and localization is introduced based on acoustic reflections. It is shown that the cross-sectional areas of structural elements can be computed directly in terms of the reflection coefficients of an optimal finite impulse response Wiener filter realized in lattice form.
The Assembly/Contingency Subsystem (ACS) is the primary communications link on board the Space Station. Any failure in a component of this system or in the external devices through which it communicates with ground-based systems will isolate the Station. The ACS software design includes a failure management capability (ACFM) that provides protocols for failure detection, isolation, and recovery (FDIR). The the ACFM design requirements as outlined in the current ACS software requirements specification document are reviewed. The activities carried out in this review include: (1) an informal, but thorough, end-to-end failure mode and effects analysis of the proposed software architecture for the ACFM; and (2) a prototype of the ACFM software, implemented as a C program under the UNIX operating system. The purpose of this review is to evaluate the FDIR protocols specified in the ACS design and the specifications themselves in light of their use in implementing the ACFM. The basis of failure detection in the ACFM is the loss of signal between the ground and the Station, which (under the appropriate circumstances) will initiate recovery to restore communications. This recovery involves the reconfiguration of the ACS to either a backup set of components or to a degraded communications mode. The initiation of recovery depends largely on the criticality of the failure mode, which is defined by tables in the ACFM and can be modified to provide a measure of flexibility in recovery procedures.
An advanced, sensor failure detection, isolation, and accomodation algorithm has been developed by NASA for the F100 turbofan engine. The algorithm takes advantage of the analytical redundancy of the sensors to improve the reliability of the sensor set. The method requires the controls computer, to determine when a sensor failure has occurred without the help of redundant hardware sensors in the control system. The controls computer provides an estimate of the correct value of the output of the failed sensor. The algorithm has been programmed in FORTRAN using a real-time microprocessor-based controls computer. A detailed description of the algorithm and its implementation on a microprocessor is given.
The objective of this study was to define and develop techniques for failure detection and isolation (FDI) algorithms for a dual fail/operational redundant strapdown inertial navigation system are defined and developed. The FDI techniques chosen include provisions for hard and soft failure detection in the context of flight control and navigation. Analyses were done to determine error detection and switching levels for the inertial navigation system, which is intended for a conventional takeoff or landing (CTOL) operating environment. In addition, investigations of false alarms and missed alarms were included for the FDI techniques developed, along with the analyses of filters to be used in conjunction with FDI processing. Two specific FDI algorithms were compared: the generalized likelihood test and the edge vector test. A deterministic digital computer simulation was used to compare and evaluate the algorithms and FDI systems.
A model is proposed to describe the pilot as a monitor of automatic landing systems. The failures treated are equivalent to the addition of a dynamic change in the mean of the observation process. The failure detection model of the pilot consists of two stages: a linear estimator (Kalman filter) and a decision mechanism based on sequential analysis. The filter equations are derived from a simplified version of the linearized dynamics of the airplane and the control loop. The perceptual observation noise is modified to include the effects of allocation of attention among the several instruments. The final result is a simple model consisting of a high-pass filter to produce the observation residuals and a decision function which is a pure integration of the residuals minus a bias term. The dynamics of a Boeing 707 were used to simulate the fully coupled final approach in a fixed-base simulator. Observers monitored the approaches and detected the failures; their performance was compared with the predictions of the model.
The design of a failure detection and identification system consists of designing a robust residual generation process and a high performance decision making process. The design of these two processes are examined separately. Residual generation is based on analytical redundancy. Redundancy relations that are insensitive to modelling errors and noise effects are important for designing robust residual generation processes. The characterization of the concept of analytical redundancy in terms of a generalized parity space provides a framework in which a systematic approach to the determination of robust redundancy relations are developed. The Bayesian approach is adopted for the design of high performance decision processes. The FDI decision problem is formulated as a Bayes sequential decision problem. Since the optimal decision rule is incomputable, a methodology for designing suboptimal rules is proposed. A numerical algorithm is developed to facilitate the design and performance evaluation of suboptimal rules.
The wind energy industry is continuously improving their operational and maintenance practice for reducing the levelized costs of energy. Anticipating failures in wind turbines enables early warnings and timely intervention, so that the costly corrective maintenance can be prevented to the largest extent possible. It also avoids production loss owing to prolonged unavailability. One critical element allowing early warning is the ability to accumulate small-magnitude symptoms resulting from the gradual degradation of wind turbine systems. Inspired by the cumulative sum control chart method, this study reports the development of a wind turbine failure detection method with such early warning capability. Specifically, the following key questions are addressed: what fault signals to accumulate, how long to accumulate, what offset to use, and how to set the alarm-triggering control limit. We apply the proposed approach to 2 years’ worth of Supervisory Control and Data Acquisition data recorded from five wind turbines. We focus our analysis on gearbox failure detection, in which the proposed approach demonstrates its ability to anticipate failure events with a good lead time.
In the paper, the results of a full-scale engine demonstration of a sensor failure detection algorithm are presented. The algorithm detects, isolates, and accommodates sensor failures using analytical redundancy. The experimental hardware, including the F100 engine, is described. Demonstration results were obtained over a large portion of a typical flight envelope for the F100 engine. They include both subsonic and supersonic conditions at both medium and full, nonafter burning, power. Estimated accuracy, minimum detectable levels of sensor failures, and failure accommodation performance for an F100 turbofan engine control system are discussed.
Algorithms for failure detection and identification for redundant noncolinear arrays of single degree of freedom gyros and accelerometers are described. These algorithms are optimum in the sense that detection occurs as soon as it is no longer possible to account for the instrument outputs as the outputs of good instruments operating within their noise tolerances, and identification occurs as soon as it is true that only a particular instrument failure could account for the actual instrument outputs within the noise tolerance of good instruments. An estimation algorithm is described which minimizes the maximum possible estimation error magnitude for the given set of instrument outputs. Monte Carlo simulation results are presented for the application of the algorithms to an inertial reference unit consisting of six gyros and six accelerometers in two alternate configurations.
The development of a solenoid valve failure detection system is described. The technique requires the addition of a radioactive gas to the propellant of a cold gas jet attitude control system. Solenoid failure is detected with an avalanche radiation detector located in the jet nozzle which senses the radiation emitted by the leaking radioactive gas. Measurements of carbon monoxide leakage rates through a Mariner type solenoid valve are presented as a function of gas activity and detector configuration. A cylindrical avalanche detector with a factor of 40 improvement in leak sensitivity is proposed for flight systems because it allows the quantity of radioactive gas that must be added to the propellant to be reduced to a practical level.
Algorithms for failure detection, isolation, and correction of redundant inertial instruments in the strapdown dodecahedron configuration are competitively evaluated in a digital computer simulation that subjects them to identical environments. Their performance is compared in terms of orientation and inertial velocity errors and in terms of missed and false alarms. The algorithms appear in the simulation program in modular form, so that they may be readily extracted for use elsewhere. The simulation program and its inputs and outputs are described. The algorithms, along with an eight algorithm that was not simulated, also compared analytically to show the relationships among them.
A model for the human observer in failure detection tasks is proposed which consists of two stages: a linear estimator and a decision mechanism. The estimator is a Kalman filter, and the decision mechanism, which is based on Wald's sequential analysis, leads to a decision function which is the integration of the filter residuals. The final result is a simple detection system which depends on only three parameters, and the sensitivity of the model to these parameters is analyzed. The results of an experiment designed to test the validity of the model are reported. The question of open and closed decision intervals as well as the generalization of the model to more complicated cases is discussed.
The formulation of the decision making of a failure detection process as a Bayes sequential decision problem (BSDP) provides a simple conceptualization of the decision rule design problem. As the optimal Bayes rule is not computable, a methodology that is based on the Baysian approach and aimed at a reduced computational requirement is developed for designing suboptimal rules. A numerical algorithm is constructed to facilitate the design and performance evaluation of these suboptimal rules. The result of applying this design methodology to an example shows that this approach is a useful one.