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Intelligent Engine Systems Work Element 1.3: Sub System Health Management

The objectives of this program were to develop health monitoring systems and physics-based fault detection models for engine sub-systems including the start, lubrication, and fuel. These models will ultimately be used to provide more effective sub-system fault identification and isolation to reduce engine maintenance costs and engine down-time. Additionally, the bearing sub-system health is addressed in this program through identification of sensing requirements, a review of available technologies and a demonstration of a demonstration of a conceptual monitoring system for a differential roller bearing. This report is divided into four sections; one for each of the subtasks. The start system subtask is documented in section 2.0, the oil system is covered in section 3.0, bearing in section 4.0, and the fuel system is presented in section 5.0.

Ashby, Malcolm

Propulsion Controls and Diagnostics Research at NASA Glenn Research Center

With the increased emphasis on aircraft safety, enhanced performance and affordability, and the need to reduce the environmental impact of aircraft, there are many new challenges being faced by the designers of aircraft propulsion systems. Also the propulsion systems required to enable the National Aeronautics and Space Administration (NASA) Vision for Space Exploration in an affordable manner will need to have high reliability, safety and autonomous operation capability. The Controls and Dynamics Branch (CDB) at NASA Glenn Research Center (GRC) in Cleveland, Ohio, is leading and participating in various projects in partnership with other organizations within GRC and across NASA, the U.S. aerospace industry, and academia to develop advanced controls and health management technologies that will help meet these challenges through the concept of Intelligent Propulsion Systems. This paper describes the current activities of the CDB under the NASA Aeronautics Research and Exploration Systems Missions. The programmatic structure of the CDB activities is described along with a brief overview of each of the CDB tasks including research objectives, technical challenges, and recent accomplishments. These tasks include active control of propulsion system components, intelligent propulsion diagnostics and control for reliable fault identification and accommodation, distributed engine control, and investigations into unsteady propulsion systems.

Garg, Sanjay

The Orion GN and C Data-Driven Flight Software Architecture for Automated Sequencing and Fault Recovery

The Orion Crew Exploration Vehicle (CET) is being designed to include significantly more automation capability than either the Space Shuttle or the International Space Station (ISS). In particular, the vehicle flight software has requirements to accommodate increasingly automated missions throughout all phases of flight. A data-driven flight software architecture will provide an evolvable automation capability to sequence through Guidance, Navigation & Control (GN&C) flight software modes and configurations while maintaining the required flexibility and human control over the automation. This flexibility is a key aspect needed to address the maturation of operational concepts, to permit ground and crew operators to gain trust in the system and mitigate unpredictability in human spaceflight. To allow for mission flexibility and reconfrgurability, a data driven approach is being taken to load the mission event plan as well cis the flight software artifacts associated with the GN&C subsystem. A database of GN&C level sequencing data is presented which manages and tracks the mission specific and algorithm parameters to provide a capability to schedule GN&C events within mission segments. The flight software data schema for performing automated mission sequencing is presented with a concept of operations for interactions with ground and onboard crew members. A prototype architecture for fault identification, isolation and recovery interactions with the automation software is presented and discussed as a forward work item.

King, Ellis

Propulsion Controls and Diagnostics Research in Support of NASA Aeronautics and Exploration Mission Programs

The Controls and Dynamics Branch (CDB) at National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) in Cleveland, Ohio, is leading and participating in various projects in partnership with other organizations within GRC and across NASA, the U.S. aerospace industry, and academia to develop advanced propulsion controls and diagnostics technologies that will help meet the challenging goals of NASA programs under the Aeronautics Research and Exploration Systems Missions. This paper provides a brief overview of the various CDB tasks in support of the NASA programs. The programmatic structure of the CDB activities is described along with a brief overview of each of the CDB tasks including research objectives, technical challenges, and recent accomplishments. These tasks include active control of propulsion system components, intelligent propulsion diagnostics and control for reliable fault identification and accommodation, distributed engine control, and investigations into unsteady propulsion systems.

Garg, Sanjay

Computational Inference of Vibratory System with Incomplete Modal Information Using Parallel, Interactive and Adaptive Markov Chains

Inverse analysis of vibratory system is an important subject in fault identification, model updating, and robust design and control. It is challenging subject because 1) the problem is oftentimes underdetermined while the measurements are limited and/or incomplete; 2) many combinations of parameters may yield results that are similar with respect to actual response measurements; and 3) uncertainties inevitably exist. The aim of this research is to leverage upon computational intelligence through statistical inference to facilitate an enhanced, probabilistic framework using incomplete modal response measurement. This new framework is built upon efficient inverse identification through optimization, whereas Bayesian inference is employed to account for the effect of uncertainties. To overcome the computational cost barrier, we adopt Markov chain Monte Carlo (MCMC) to characterize the target function/distribution. Instead of using single Markov chain in conventional Bayesian approach, we develop a new sampling theory with multiple parallel, interactive and adaptive Markov chains and incorporate it into Bayesian inference. This can harness the collective power of these Markov chains to realize the concurrent search of multiple local optima. The number of required Markov chains and their respective initial model parameters are automatically determined via Monte Carlo simulation-based sample pre-screening followed by K-means clustering analysis. These enhancements can effectively address the aforementioned challenges in finite element inverse analysis. The validity of this framework is systematically demonstrated through case studies.

K Zhou

Digital Twin Enabling Technologies for Online Condition Monitoring of Nuclear Power Plant Components

Online condition monitoring is an area of active research that may enable improved scheduling, maintenance, and safety of nuclear power plant components, reducing unnecessary derate while simultaneously improving operational capacity. Digital twins are one avenue to conduct online condition monitoring and are currently being explored by national laboratories and universities alike. Digital twins for online condition monitoring are, in essence, state concurrent models that emulate a physical process which predicts a parameter and compares it against a measured value. However, digital twins may also provide additional insights by combining and interpreting various sources of information. These insights may be used for preventative maintenance scheduling optimization or early fault detection and are projected to be valuable for meeting requirements under 10 CFR 50.55a. However, digital twin technologies are still under significant development; quantifying model uncertainties, improving unique fault identification, and multimodal sensor fusion are some areas under investigation. Therefore, in this work, we discuss and review the various enabling technologies, in the form of advanced sensors, instrumentation, and modelling methods, that may be used to implement and enhance digital twins for online condition monitoring. A potential use case for pump-motors is presented to demonstrate how these various pieces of enabling digital twin technologies may integrated together for online condition monitoring. Challenges and opportunities associated with the pump-motor digital twin enabling technologies are also identified and discussed.

22 GENERAL STUDIES OF NUCLEAR REACTORS

Digital-Twin-Enabling Technologies for Online Condition Monitoring of Nuclear Power Plant Components

Online condition monitoring is an area of active research that may enable improved scheduling, maintenance, and safety of nuclear power plant components, reducing unnecessary derates while simultaneously improving operational capacity. Digital twins are one avenue to conduct online condition monitoring and are currently being explored by national laboratories and universities alike. Digital twins for online condition monitoring are, in essence, state concurrent models that emulate a physical process which predicts a parameter and compares it against a measured value. However, digital twins may also provide additional insights by combining and interpreting various sources of information. These insights may be used for preventative maintenance scheduling optimization or early fault detection and are projected to be valuable for meeting requirements under 10 CFR 50.55a. However, digital twin technologies are still under significant development; quantifying model uncertainties, improving unique fault identification, and multimodal sensor fusion are some areas under investigation. Therefore, in this work, we discuss and review the various enabling technologies, in the form of advanced sensors, instrumentation, and modelling methods, that may be used to implement and enhance digital twins for online condition monitoring. A potential use case for pump-motors is presented to demonstrate how these various pieces of enabling digital twin technologies may integrated together for online condition monitoring. Challenges and opportunities associated with the pump-motor digital twin enabling technologies are also identified and discussed.

22 - GENERAL STUDIES OF NUCLEAR REACTORS

Identification of active faults in enlarged stereo models of Skylab S-190B photographs

Most of the physiographic indicators of recent movement known to be present along the Indio Hills segment of the San Andreas fault zone can be identified on enlarged Skylab S-190B stereo photographs. These include offset streams, beheaded streams, offset fans, shutter ridges, linear valleys, scarps and vegetation anomalies. Where physiographic indicators of recent movement are present, the S-190B system affords the necessary resolution and stereoscopy for distinguishing activate from inactive faults.

Merifield, P. M.

Dynamic Structural Fault Detection and Identification

Aircraft structures are designed to guarantee safety of flight in some required operational envelope. When the aircraft becomes structurally impaired, safety of flight may not be guaranteed within that previously safe operational envelope. In this case the safe operational envelope must be redefined in-flight and a means to prevent excursion from this new envelope must be implemented. A specific structural failure mode that may result in a reduced safe operating envelope, the exceedance of which could lead to catastrophic structural failure of the aircraft, will be addressed. The goal of the DFEAP program is the detection of this failure mode coupled with flight controls adaptation to limit critical loads in the damaged aircraft structure. The DFEAP program is working with an F/A-18 aircraft model. The composite wing skins are bonded to metallic spars in the wing substructure. Over time, it is possible that this bonding can deteriorate due to fatigue. In this case, the ability of the wing spar to transfer loading between the wing skins is reduced. This failure mode can translate to a reduced allowable compressive strain on the wing skin and could lead to catastrophic wing buckling if load limiting of the wing structure is not applied. The DFEAP program will make use of a simplified wing strain model for the healthy aircraft. The outputs of this model will be compared in real-time to onboard strain measurements at several locations on the aircraft wing. A damage condition is declared at a given location when the strain measurements differ sufficiently from the strain model. Parameter identification of the damaged structure wing strain parameters will be employed to provide load limiting control adaptation for the aircraft. This paper will discuss the simplified strain models used in the implementation and their interaction with the strain sensor measurements. Also discussed will be the damage detection and identification schemes employed and the means by which the damaged aircraft parameters will be used to provide load limiting that keeps the aircraft within the safe operational envelope.

Smith, Timothy

Software-implemented fault insertion: An FTMP example

This report presents a model for fault insertion through software; describes its implementation on a fault-tolerant computer, FTMP; presents a summary of fault detection, identification, and reconfiguration data collected with software-implemented fault insertion; and compares the results to hardware fault insertion data. Experimental results show detection time to be a function of time of insertion and system workload. For the fault detection time, there is no correlation between software-inserted faults and hardware-inserted faults; this is because hardware-inserted faults must manifest as errors before detection, whereas software-inserted faults immediately exercise the error detection mechanisms. In summary, the software-implemented fault insertion is able to be used as an evaluation technique for the fault-handling capabilities of a system in fault detection, identification and recovery. Although the software-inserted faults do not map directly to hardware-inserted faults, experiments show software-implemented fault insertion is capable of emulating hardware fault insertion, with greater ease and automation.

Czeck, Edward W.

Hardware fault insertion and instrumentation system: Mechanization and validation

Automated test capability for extensive low-level hardware fault insertion testing is developed. The test capability is used to calibrate fault detection coverage and associated latency times as relevant to projecting overall system reliability. Described are modifications made to the NASA Ames Reconfigurable Flight Control System (RDFCS) Facility to fully automate the total test loop involving the Draper Laboratories' Fault Injector Unit. The automated capability provided included the application of sequences of simulated low-level hardware faults, the precise measurement of fault latency times, the identification of fault symptoms, and bulk storage of test case results. A PDP-11/60 served as a test coordinator, and a PDP-11/04 as an instrumentation device. The fault injector was controlled by applications test software in the PDP-11/60, rather than by manual commands from a terminal keyboard. The time base was especially developed for this application to use a variety of signal sources in the system simulator.

Benson, J. W.

Neural network application to comprehensive engine diagnostics

We have previously reported on the use of neural networks for detection and identification of faults in complex microprocessor controlled powertrain systems. The data analyzed in those studies consisted of the full spectrum of signals passing between the engine and the real-time microprocessor controller. The specific task of the classification system was to classify system operation as nominal or abnormal and to identify the fault present. The primary concern in earlier work was the identification of faults, in sensors or actuators in the powertrain system as it was exercised over its full operating range. The use of data from a variety of sources, each contributing some potentially useful information to the classification task, is commonly referred to as sensor fusion and typifies the type of problems successfully addressed using neural networks. In this work we explore the application of neural networks to a different diagnostic problem, the diagnosis of faults in newly manufactured engines and the utility of neural networks for process control.

Marko, Kenneth A.

Rotorcraft Diagnostics

Health management (HM) in any engineering systems requires adequate understanding about the system s functioning; a sufficient amount of monitored data; the capability to extract, analyze, and collate information; and the capability to combine understanding and information for HM-related estimation and decision-making. Rotorcraft systems are, in general, highly complex. Obtaining adequate understanding about functioning of such systems is quite difficult, because of the proprietary (restricted access) nature of their designs and dynamic models. Development of an EIM (exact inverse map) solution for rotorcraft requires a process that can overcome the abovementioned difficulties and maximally utilize monitored information for HM facilitation via employing advanced analytic techniques. The goal was to develop a versatile HM solution for rotorcraft for facilitation of the Condition Based Maintenance Plus (CBM+) capabilities. The effort was geared towards developing analytic and reasoning techniques, and proving the ability to embed the required capabilities on a rotorcraft platform, paving the way for implementing the solution on an aircraft-level system for consolidation and reporting. The solution for rotorcraft can he used offboard or embedded directly onto a rotorcraft system. The envisioned solution utilizes available monitored and archived data for real-time fault detection and identification, failure precursor identification, and offline fault detection and diagnostics, health condition forecasting, optimal guided troubleshooting, and maintenance decision support. A variant of the onboard version is a self-contained hardware and software (HW+SW) package that can be embedded on rotorcraft systems. The HM solution comprises components that gather/ingest data and information, perform information/feature extraction, analyze information in conjunction with the dependency/diagnostic model of the target system, facilitate optimal guided troubleshooting, and offer decision support for optimal maintenance.

Haste, Deepak

Fault detection, isolation and reconfiguration in FTMP Methods and experimental results

The Fault-Tolerant Multiprocessor (FTMP) is a highly reliable computer designed to meet a goal of 10 to the -10th failures per hour and built with the objective of flying an active-control transport aircraft. Fault detection, identification, and recovery software is described, and experimental results obtained by injecting faults in the pin level in the FTMP are presented. Over 21,000 faults were injected in the CPU, memory, bus interface circuits, and error detection, masking, and error reporting circuits of one LRU of the multiprocessor. Detection, isolation, and reconfiguration times were recorded for each fault, and the results were found to agree well with earlier assumptions made in reliability modeling.

Lala, J. H.

An Integrated Framework for Model-Based Distributed Diagnosis and Prognosis

Diagnosis and prognosis are necessary tasks for system reconfiguration and fault-adaptive control in complex systems. Diagnosis consists of detection, isolation and identification of faults, while prognosis consists of prediction of the remaining useful life of systems. This paper presents a novel integrated framework for model-based distributed diagnosis and prognosis, where system decomposition is used to enable the diagnosis and prognosis tasks to be performed in a distributed way. We show how different submodels can be automatically constructed to solve the local diagnosis and prognosis problems. We illustrate our approach using a simulated four-wheeled rover for different fault scenarios. Our experiments show that our approach correctly performs distributed fault diagnosis and prognosis in an efficient and robust manner.

Bregon, Anibal

Identifiability of Additive, Time-Varying Actuator and Sensor Faults by State Augmentation

Recent work has provided a set of necessary and sucient conditions for identifiability of additive step faults (e.g., lock-in-place actuator faults, constant bias in the sensors) using state augmentation. This paper extends these results to an important class of faults which may affect linear, time-invariant systems. In particular, the faults under consideration are those which vary with time and affect the system dynamics additively. Such faults may manifest themselves in aircraft as, for example, control surface oscillations, control surface runaway, and sensor drift. The set of necessary and sucient conditions presented in this paper are general, and apply when a class of time-varying faults affects arbitrary combinations of actuators and sensors. The results in the main theorems are illustrated by two case studies, which provide some insight into how the conditions may be used to check the theoretical identifiability of fault configurations of interest for a given system. It is shown that while state augmentation can be used to identify certain fault configurations, other fault configurations are theoretically impossible to identify using state augmentation, giving practitioners valuable insight into such situations. That is, the limitations of state augmentation for a given system and configuration of faults are made explicit. Another limitation of model-based methods is that there can be large numbers of fault configurations, thus making identification of all possible configurations impractical. However, the theoretical identifiability of known, credible fault configurations can be tested using the theorems presented in this paper, which can then assist the efforts of fault identification practitioners.

Upchurch, Jason M.

Applications of Fault Detection in Vibrating Structures

Structural fault detection and identification remains an area of active research. Solutions to fault detection and identification may be based on subtle changes in the time series history of vibration signals originating from various sensor locations throughout the structure. The purpose of this paper is to document the application of vibration based fault detection methods applied to several structures. Overall, this paper demonstrates the utility of vibration based methods for fault detection in a controlled laboratory setting and limitations of applying the same methods to a similar structure during flight on an experimental subscale aircraft.

Eure, Kenneth W.

Flight elements: Fault detection and fault management

Fault management for an intelligent computational system must be developed using a top down integrated engineering approach. An approach proposed includes integrating the overall environment involving sensors and their associated data; design knowledge capture; operations; fault detection, identification, and reconfiguration; testability; causal models including digraph matrix analysis; and overall performance impacts on the hardware and software architecture. Implementation of the concept to achieve a real time intelligent fault detection and management system will be accomplished via the implementation of several objectives, which are: Development of fault tolerant/FDIR requirement and specification from a systems level which will carry through from conceptual design through implementation and mission operations; Implementation of monitoring, diagnosis, and reconfiguration at all system levels providing fault isolation and system integration; Optimize system operations to manage degraded system performance through system integration; and Lower development and operations costs through the implementation of an intelligent real time fault detection and fault management system and an information management system.

Lum, H.