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At least 595 records · Page 33

CARE 3 User's Workshop

A user's workshop for CARE 3, a reliability assessment tool designed and developed especially for the evaluation of high reliability fault tolerant digital systems, was held at NASA Langley Research Center on October 6 to 7, 1987. The main purpose of the workshop was to assess the evolutionary status of CARE 3. The activities of the workshop are documented and papers are included by user's of CARE 3 and NASA. Features and limitations of CARE 3 and comparisons to other tools are presented. The conclusions to a workshop questionaire are also discussed.

Source record↗

Failure modes and effects analysis automation

A failure modes and effects analysis (FMEA) assistant was implemented as a knowledge based system and will be used during design of the Space Station to aid engineers in performing the complex task of tracking failures throughout the entire design effort. The three major directions in which automation was pursued were the clerical components of the FMEA process, the knowledge acquisition aspects of FMEA, and the failure propagation/analysis portions of the FMEA task. The system is accessible to design, safety, and reliability engineers at single user workstations and, although not designed to replace conventional FMEA, it is expected to decrease by many man years the time required to perform the analysis.

Kamhieh, Cynthia H.↗

Integrated control and health monitoring capacitive displacement sensor development task. Orbit transfer rocket engine technology program

The development of a miniature multifunction turbomachinery shaft displacement sensor using state-of-the-art non-contract capacitive sensing technology is described. Axial displacement, radial displacement, and speed are sensed using a single probe within the envelope normally required for a single function. A survey of displacement sensing technology is summarized including inductive, capacitive, optical and ultrasonic techniques. The design and operation of an experimental triple function sensor is described. Test results are included showing calibration tests and simultaneous dynamic testing of multiple functions. Recommendations for design changes are made to improve low temperature performance, reliability, and for design of a flight type signal conditioning unit.

Collamore, Frank N.↗

The Characteristics of Two Model Six-blade Counterrotating Pusher Propellers of Conventional and Improved Aerodynamic Design

Two airfoil plans were used for propeller blades. One is modified Clark Y section designed for structural reliability and the second an NACA 16 airfoil section designed to produce minimum aerodynamic losses. At low air speeds, the propeller designed for aerodynamic effects showed a gain of from 1.5 to 4.0 percent in propulsive efficiency over the conventional type depending on the pitch. Because of the numerous variables involved, the effect of each one on the aerodynamic characteristics of the propellers could not be isolated.

PROPELLERS - PROPULSIVE EFFICIENCY↗

Reliability Growth in Space Life Support Systems

A hardware system's failure rate often increases over time due to wear and aging, but not always. Some systems instead show reliability growth, a decreasing failure rate with time, due to effective failure analysis and remedial hardware upgrades. Reliability grows when failure causes are removed by improved design. A mathematical reliability growth model allows the reliability growth rate to be computed from the failure data. The space shuttle was extensively maintained, refurbished, and upgraded after each flight and it experienced significant reliability growth during its operational life. In contrast, the International Space Station (ISS) is much more difficult to maintain and upgrade and its failure rate has been constant over time. The ISS Carbon Dioxide Removal Assembly (CDRA) reliability has slightly decreased. Failures on ISS and with the ISS CDRA continue to be a challenge.

life support↗

Stellarators as a fast path to fusion

Herein this paper is focused on three points: (1) overcoming obstacles to tokamak power plants may require a configuration modification as large as that of a stellarator. (2) The demonstrated reliability of the computational design of stellarators should change fusion strategy. (3) Deployment of carbon-free energy sources is mandated by the thirty-year doubling of carbon dioxide emissions. Carbon-free energy options must be developed and fully deployed within a few doubling times. Unit size and cost of electricity are only relevant in comparison to alternative worldwide energy solutions. Intermittency, site specificity, waste management, and nuclear proliferation make fusion attractive as the basis for a carbon-free energy system compared to the alternatives. Nonetheless, fusion is not an option for deployment until a power plant has successfully operated. A critical element in a minimal time and risk program is the use of computational design as opposed to just extrapolation. Only the stellarator has an empirical demonstration of the reliable computational design through large changes in configuration properties and scale. The computational design of stellarators should proceed while the inventions necessary for a more tokamak-like power plant are sought. The cost of computational design is extremely small, but adequate time is required for the development of ideas that maximize attractiveness and minimize risk. Rapid power-plant construction without many intermediate steps may seem risky, but the price is small compared to the cost of trillions of dollars for each year's delay in addressing carbon-dioxide emissions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Highly Survivable Avionics Systems for Long-Term Deep Space Exploration

The design of highly survivable avionics systems for long-term (> 10 years) exploration of space is an essential technology for all current and future missions in the Outer Planets roadmap. Long-term exposure to extreme environmental conditions such as high radiation and low-temperatures make survivability in space a major challenge. Moreover, current and future missions are increasingly using commercial technology such as deep sub-micron (0.25 microns) fabrication processes with specialized circuit designs, commercial interfaces, processors, memory, and other commercial off the shelf components that were not designed for long-term survivability in space. Therefore, the design of highly reliable, and available systems for the exploration of Europa, Pluto and other destinations in deep-space require a comprehensive and fresh approach to this problem. This paper summarizes work in progress in three different areas: a framework for the design of highly reliable and highly available space avionics systems, distributed reliable computing architecture, and Guarded Software Upgrading (GSU) techniques for software upgrading during long-term missions. Additional information is contained in the original extended abstract.

Alkalai, L.↗

Modeling and Simulation of Reliability & Maintainability Parameters for Reusable Launch Vehicles using Design of Experiments

This paper describes the development of a methodology for estimating reliability and maintainability distribution parameters for a reusable launch vehicle. A disciplinary analysis code and experimental designs are used to construct approximation models for performance characteristics. These models are then used in a simulation study to estimate performance characteristic distributions efficiently. The effectiveness and limitations of the developed methodology for launch vehicle operations simulations are also discussed.

Unal, Resit↗

Structural Reliability Analysis and Optimization: Use of Approximations

This report is intended for the demonstration of function approximation concepts and their applicability in reliability analysis and design. Particularly, approximations in the calculation of the safety index, failure probability and structural optimization (modification of design variables) are developed. With this scope in mind, extensive details on probability theory are avoided. Definitions relevant to the stated objectives have been taken from standard text books. The idea of function approximations is to minimize the repetitive use of computationally intensive calculations by replacing them with simpler closed-form equations, which could be nonlinear. Typically, the approximations provide good accuracy around the points where they are constructed, and they need to be periodically updated to extend their utility. There are approximations in calculating the failure probability of a limit state function. The first one, which is most commonly discussed, is how the limit state is approximated at the design point. Most of the time this could be a first-order Taylor series expansion, also known as the First Order Reliability Method (FORM), or a second-order Taylor series expansion (paraboloid), also known as the Second Order Reliability Method (SORM). From the computational procedure point of view, this step comes after the design point identification; however, the order of approximation for the probability of failure calculation is discussed first, and it is denoted by either FORM or SORM. The other approximation of interest is how the design point, or the most probable failure point (MPP), is identified. For iteratively finding this point, again the limit state is approximated. The accuracy and efficiency of the approximations make the search process quite practical for analysis intensive approaches such as the finite element methods; therefore, the crux of this research is to develop excellent approximations for MPP identification and also different approximations including the higher-order reliability methods (HORM) for representing the failure surface. This report is divided into several parts to emphasize different segments of the structural reliability analysis and design. Broadly, it consists of mathematical foundations, methods and applications. Chapter I discusses the fundamental definitions of the probability theory, which are mostly available in standard text books. Probability density function descriptions relevant to this work are addressed. In Chapter 2, the concept and utility of function approximation are discussed for a general application in engineering analysis. Various forms of function representations and the latest developments in nonlinear adaptive approximations are presented with comparison studies. Research work accomplished in reliability analysis is presented in Chapter 3. First, the definition of safety index and most probable point of failure are introduced. Efficient ways of computing the safety index with a fewer number of iterations is emphasized. In chapter 4, the probability of failure prediction is presented using first-order, second-order and higher-order methods. System reliability methods are discussed in chapter 5. Chapter 6 presents optimization techniques for the modification and redistribution of structural sizes for improving the structural reliability. The report also contains several appendices on probability parameters.

Grandhi, Ramana V.↗

Manned systems utilization analysis (study 2.1). Volume 1: Executive summary

Man's contribution to the achievement of scientific mission objectives in the space environment is investigated in terms of potential improvement in future applications of scientific instruments relative to the need for interactive manned support operations. Emphasis is placed on experience gained from space programs and the development of empirical techniques to associate the benefit of repair and management actions. Design features are addressed in terms of weight, volume, and reliability associated with designing for space maintenance. The results of the following programs are examined: the OVI series of automated spacecraft; the OSO-7 automated spacecraft; and the Skylab S-056 X-ray telescope experiment in the ATM. It is shown that orbital maintenance is the most realistic means of achieving high system availabilities for scientific instruments.

Wolfe, R. R.↗

Preliminary Measurements of Partial Discharge Inception Voltage Degradation with Constant Temperature Aging of Magnet Wire Twisted Pairs for Electric Aircraft Motors

Electric aircraft require high reliability electric motors to meet the stringent safety standards of the aviation industry. Motor winding insulation lifetime and reliability models for electric aircraft applications are needed to enable design of high reliability and high-performance electric motors for aviation applications. Three primary stresses effect the lifetime of motor winding insulation: thermochemical, mechanical, and electrical. This paper presents preliminary experiments on twisted pairs of magnet wire targeting understanding the thermo-chemical degradation of motor winding insulation through constant temperature thermal aging. Three types of magnet wire twisted pairs where tested: polyimide insulated magnet wire, epoxy coated polyimide insulated magnet wire, and epoxy potted polyimide magnet wire. The degradation of the samples over time at temperature was tracked using partial discharge inception voltage measurements. These initial experiments were used for development of procedures and expertise in partial discharge testing and thermo-chemical aging to inform future testing. The preliminary nature of these experiments should be noted when viewing the results. Lessons learned from the experiments are documented.

Thomas Tallerico↗

Cascade Optimization Strategy for Aircraft and Air-Breathing Propulsion System Concepts

Design optimization for subsonic and supersonic aircraft and for air-breathing propulsion engine concepts has been accomplished by soft-coupling the Flight Optimization System (FLOPS) and the NASA Engine Performance Program analyzer (NEPP), to the NASA Lewis multidisciplinary optimization tool COMETBOARDS. Aircraft and engine design problems, with their associated constraints and design variables, were cast as nonlinear optimization problems with aircraft weight and engine thrust as the respective merit functions. Because of the diversity of constraint types and the overall distortion of the design space, the most reliable single optimization algorithm available in COMETBOARDS could not produce a satisfactory feasible optimum solution. Some of COMETBOARDS' unique features, which include a cascade strategy, variable and constraint formulations, and scaling devised especially for difficult multidisciplinary applications, successfully optimized the performance of both aircraft and engines. The cascade method has two principal steps: In the first, the solution initiates from a user-specified design and optimizer, in the second, the optimum design obtained in the first step with some random perturbation is used to begin the next specified optimizer. The second step is repeated for a specified sequence of optimizers or until a successful solution of the problem is achieved. A successful solution should satisfy the specified convergence criteria and have several active constraints but no violated constraints. The cascade strategy available in the combined COMETBOARDS, FLOPS, and NEPP design tool converges to the same global optimum solution even when it starts from different design points. This reliable and robust design tool eliminates manual intervention in the design of aircraft and of air-breathing propulsion engines where it eases the cycle analysis procedures. The combined code is also much easier to use, which is an added benefit. This paper describes COMETBOARDS and its cascade strategy and illustrates the capability of the combined design tool through the optimization of a subsonic aircraft and a high-bypass-turbofan wave-rotor-topped engine.

Patnaik, Surya N.↗

Reliability of area array packages with 1500-2500 I/Os

This report first provides a literature survey for designing, manufacturing, and reliability test results for area array packages with 1500 to 2500 inputs/outputs (I/Os). It then presents test matrix on design, yield, and workmanship defects on assembly and environmental testing, including thermal cycle and mechanical drop-test evaluation results for FCBGA1704, FPBGA432, and PBGA676 I/Os packages assembled onto printed circuit/wiring boards (PCBs/PWBs). Finally, it summarizes lessons learned from test results for assembly and environmental testing along with optical, scanning electron microscopy (SEM), and x-ray photomicrographs showing damage progress.

Ghaffarian, Reza↗

NLS propulsion design considerations

The new launch system is an evolutionary launch capability to meet the future national space launch need with significant improvements in operability and corresponding reduction in per flight costs. This improved capability is being achieved by: (1) providing the design, facilities, and infrastructure for cost effective operations; (2) developing a low cost, robust liquid hydrogen and liquid oxygen engine; and (3) using the capability and infrastructure of current tankage and shroud elements to derive a operationally efficient and highly reliable vehicle. The design and operational features of the propulsion system are key considerations in achieving the required reliability, operability and dependability. These design considerations will enable cost effective transportation to low earth orbit for a family of vehicles from 20 K to over 100 K lbs payload class.

Worlund, A. L.↗

Special tooling for joining tubing in place

The Saturn S-II stage and the Apollo spacecraft will include in their design and construction various pressurized tubing systems that will encounter service temperatures of 280° F to -423° F. Design engineering and reliability requirements and weight restrict ions have dictated new concepts to assure leak-tight joints for rocket engine fuel lines, pressurization systems, utility systems, and hydraulic systems. An investigation was initiated at North American Aviation, Inc., Space and Information Systems Division, utilizing the in-place automatically controlled miniaturized fusion-welding equipment originally developed by the Los Angeles Division of NAA and modified to meet the needs of Apollo and Saturn welded tubular systems. The objective was to make circumferential flanged weld joints in any position in 304L stainless for Saturn S-II and sleeve-type joints in 304L for Apollo. Inconel X, commercially pure titanium, 5052-0 aluminum, and 6061 T6 aluminum were also tested experimentally. Extensive environmental, static, and dynamic testing programs were conducted to determine the as-welded mechanical properties, design allowables, and reliability for the tube joints. This paper discusses both the experimental and production phases. Subsequently, the new tube welding process was approved and incorporated into manufacturing fabrication methods for tube joining.

Saturn S-II stage↗

Error Propagation Analysis in the SAE Architecture Analysis and Design Language (AADL) and the EDICT Tool Framework

This report documents the capabilities of the EDICT tools for error modeling and error propagation analysis when operating with models defined in the Architecture Analysis & Design Language (AADL). We discuss our experience using the EDICT error analysis capabilities on a model of the Scalable Processor-Independent Design for Enhanced Reliability (SPIDER) architecture that uses the Reliable Optical Bus (ROBUS). Based on these experiences we draw some initial conclusions about model based design techniques for error modeling and analysis of highly reliable computing architectures.

LaValley, Brian W.↗

A High-Speed High-Power-Density Non-Heavy Rare-Earth Permanent Magnet Traction Motor

There has been a global push for higher torque density and lower cost traction motors. The use of non-heavy rare-earth (non-HRE) permanent magnet materials in traction motors are being investigated for the sustainability, profitability and affordability of electric vehicles and to broaden their adoption. A 20,000-rpm permanent magnet traction motor using non-HRE magnet materials is proposed. A dual three-phase winding configuration driven by a segmented dual three-phase drive is proposed to reduce the current ripple, and as a result, the DC Link capacitor, as well as to ease the voltage constraint at high speed and eliminate any risk of uncontrolled regeneration. Furthermore, the dual winding configuration enables a fault tolerant design which is useful for reliability. The paper presents comprehensive electromagnetic, thermal and mechanical designs and analyses using an integrated approach. The results have shown that the design is robust against demagnetization and confirmed its thermal and mechanical viability.

47 OTHER INSTRUMENTATION↗

In Situ ATR-FTIR Study of the Cathode–Electrolyte Interphase: Electrolyte Solution Structure, Transition Metal Redox, and Surface Layer Evolution

We present a study of the lithium nickel manganese cobalt oxide (LiNi 0.6 Mn 0.2 Co 0.2 O 2 , NMC622) cathode-electrolyte interphase (CEI) during galvanostatic charging and discharging using in situ attenuated total reflectance Fourier transform infrared (ATR-FTIR) methods to investigate the voltage dependent electrolyte solution structure changes at the interface, transition metal (TM) redox chemistry, and cathode/electrolyte interfacial layer evolution. Furthermore, our in situ cell design provides both reliable electrochemical device testing and strong FTIR vibrational absorption signals near the cathode surface. Specifically, advanced spectral analysis elucidates changes of near-surface Li+ ion (de)solvation by solvent molecules during galvanostatic cycling. Moreover, cathode metal-oxygen vibrational absorptions, sensitive to TM redox behaviors and subsequent local structural variations, were correlated to cathode de-lithiation (and lithiation) and electrolyte solution structure changes. In addition, we have detected the formation and evolution of a CEI surface layer on the NMC622 cathode that contributes to the cell's capacity fade.

25 ENERGY STORAGE↗