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At least 613 records · Page 34

R2U2 in Space: System and Software Health Management for Small Satellites

In order for small but complex systems like rovers, SmallSats, or Unmanned Aircraft (UAS) to operate autonomously, they must have a real-time solution for assessing their own system health. System and Software Health Management (SHM) enables better detection of faulty sensors and software problems, and enables better fault management including mitigation of unpredicted fault scenarios in the absence of a human on-board. In recent work, we have developed a Responsive, Realizable, Unobtrusive Unit (R2U2) for on-board SHM of autonomous UAS and demonstrated its ability to detect faults during flight time. These faults, from sensor failures, to software problems, to malicious security attacks, can present as transient temporal faults that even humans are challenged to find. An R2U2 congfiuration is a modular combination of multiple types of temporal logic runtime observers with fault-specic Bayesian Nets and sensor filters. R2U2 reasons about both on-board hardware and software components; R2U2 itself can be instantiated as an independent FPGA (Field-Programmable Gate Array)-based conguration or as a software component running independently from other software on-board. Small satellites, such as CubeSats, also require on-board SHM and failure mitigation, as limited telemetry bandwidth does not allow the transmission of the entire system state for ground-based health management. However, the autonomous operation of satellites brings a set of challenges different from UAS, including the effects of radiation on non-rad-hard, low-cost components, and the harsher environment of space. We surmise that a new extension of R2U2 could be adapted to help better detect, for example, radiation errors in cheaper COTS (Commercial Off the Shelf) (not rad-hard) components often used in small space systems. Since small satellites often operate in coordination, we will also examine new ways of distributed monitoring of their communication and cooperation and real-time detection of off-nominal situations utilizing multiple satellites. This talk will discuss preliminary work and ideas for building on terrestrial success of system and software health management for the harsher, and differently challenging, environment of space.

Runtime Verification & Validation↗

Correlation study between vibrational environmental and failure rates of civil helicopter components

An investigation of two selected helicopter types, namely, the Models 206A/B and 212, is reported. An analysis of the available vibration and reliability data for these two helicopter types resulted in the selection of ten components located in five different areas of the helicopter and consisting primarily of instruments, electrical components, and other noncritical flight hardware. The potential for advanced technology in suppressing vibration in helicopters was assessed. The are still several unknowns concerning both the vibration environment and the reliability of helicopter noncritical flight components. Vibration data for the selected components were either insufficient or inappropriate. The maintenance data examined for the selected components were inappropriate due to variations in failure mode identification, inconsistent reporting, or inaccurate informaton.

Alaniz, O.↗

SSME Condition Monitoring Using Neural Networks and Plume Spectral Signatures

For a variety of reasons, condition monitoring of the Space Shuttle Main Engine (SSME) has become an important concern for both ground tests and in-flight operation. The complexities of the SSME suggest that active, real-time condition monitoring should be performed to avoid large-scale or catastrophic failure of the engine. In 1986, the SSME became the subject of a plume emission spectroscopy project at NASA's Marshall Space Flight Center (MSFC). Since then, plume emission spectroscopy has recorded many nominal tests and the qualitative spectral features of the SSME plume are now well established. Significant discoveries made with both wide-band and narrow-band plume emission spectroscopy systems led MSFC to develop the Optical Plume Anomaly Detection (OPAD) system. The OPAD system is designed to provide condition monitoring of the SSME during ground-level testing. The operational health of the engine is achieved through the acquisition of spectrally resolved plume emissions and the subsequent identification of abnormal emission levels in the plume indicative of engine erosion or component failure. Eventually, OPAD, or a derivative of the technology, could find its way on to an actual space vehicle and provide in-flight engine condition monitoring. This technology step, however, will require miniaturized hardware capable of processing plume spectral data in real-time. An objective of OPAD condition monitoring is to determine how much of an element is present in the SSME plume. The basic premise is that by knowing the element and its concentration, this could be related back to the health of components within the engine. For example, an abnormal amount of silver in the plume might signify increased wear or deterioration of a particular bearing in the engine. Once an anomaly is identified, the engine could be shut down before catastrophic failure occurs. Currently, element concentrations in the plume are determined iteratively with the help of a non-linear computer code called SPECTRA, developed at the USAF Arnold Engineering Development Center. Ostensibly, the code produces intensity versus wavelength plots (i.e., spectra) when inputs such as element concentrations, reaction temperature, and reaction pressure are provided. However, in order to provide a higher-level analysis, element concentration is not specified explicitly as an input. Instead, two quantum variables, number density and broadening parameter, are used. Past experience with OPAD data analysis has revealed that the region of primary interest in any SSME plume spectrum lies in the wavelength band of 3300 A to 4330 A. Experience has also revealed that some elements, such as iron, cobalt and nickel, cause multiple peaks over the chosen wavelength range whereas other elements (magnesium, for example) have a few, relatively isolated peaks in the chosen wavelength range. Iteration with SPECTRA as a part of OPAD data analysis is an incredibly labor intensive task and not one to be performed by hand. What is really needed is the "inverse" of the computer code but the mathematical model for the inverse mapping is tenuous at best. However, building generalized models based upon known input/output mappings while ignoring details of the governing physical model is possible using neural networks. Thus the objective of the research project described herein was to quickly and accurately predict combustion temperature and element concentrations (i.e., number density and broadening parameter) from a given spectrum using a neural network. In other words, a neural network had to be developed that would provide a generalized "inverse" of the computer code SPECTRA.

Hopkins, Randall↗

Development of biaxial test fixture includes cryogenic application

Test fixture has the capability of producing biaxial stress fields in test specimens to the point of failure. It determines biaxial stress by dividing the applied load by the net cross section. With modification it can evaluate materials, design concepts, and production hardware at cryogenic temperatures.

Helf, J. C.↗

Design and evaluation of a fault-tolerant multiprocessor using hardware recovery blocks

Attention is given to the design and evaluation of a fault-tolerant multiprocessor whose rollback recovery mechanism is based on hardware recovery blocks constructed by consecutive state-save operations and several state-save units in every processor and memory module. Upon detection of failure, the multiprocessor reconfigures itself to replace the faulty module and the process originally assigned to the faulty module retreats to one of the previously saved states, in order to resume fault-free execution. A mathematical model is proposed for the calculation of multistep rollback recovery coverage and the risk of restart when all available saved states are exhausted. The mean and the variance of task execution time with the occurrence of rollbacks and/or restarts are evaluated.

Lee, Y.-H.↗

Evaluate the application of modal test and analysis processes to structural fault detection in MSFC-STS project elements

The Space Transportation System (STS) is a very complex and expensive flight system which is intended to carry payloads into low Earth orbit and return. A catastrophic failure of the STS (such as experienced in the 51-L incident) results in the loss of both human life as well as very expensive hardware. One impact of this incident was to reaffirm the need to do everything possible to insure the integrity and reliability of the STS is sufficient to produce a safe flight. One means of achieving this goal is to expand the number of inspection technologies available for use on the STS. The purpose was to begin to evaluate the possible use of assessing the structural integrity of STS components for which Marshall Space Flight Center (MSFC) has responsibility. This entailed reviewing the available literature and determining a low-level experimental program which could be performed by MSFC and would help establish the feasibility of using this technology for structural fault detection.

Springer, William T.↗

On developing the local research environment of the 1990s - The Space Station era

A requirements analysis for the Space Station's polar platform data system has been performed. Based upon this analysis, a cluster, layered cluster, and layered-modular implementation of one specific module within the Eos Data and Information System (EosDIS), an active data base for satellite remote sensing research has been developed. It is found that a distributed system based on a layered-modular architecture and employing current generation work station technologies has the requisite attributes ascribed by the remote sensing research community. Although, based on benchmark testing, probabilistic analysis, failure analysis and user-survey technique analysis, it is found that this architecture presents some operational shortcomings that will not be alleviated with new hardware or software developments. Consequently, the potential of a fully-modular layered architectural design for meeting the needs of Eos researchers has also been evaluated, concluding that it would be well suited to the evolving requirements of this multidisciplinary research community.

Chase, Robert↗

Next Generation Wiring

Wiring is a major operational component on aerospace hardware that accounts for substantial weight and volumetric space. Over time wire insulation can age and fail, often leading to catastrophic events such as system failure or fire. The next generation of wiring must be reliable and sustainable over long periods of time. These features will be achieved by the development of a wire insulation capable of autonomous self-healing that mitigates failure before it reaches a catastrophic level. In order to develop a self-healing insulation material, three steps must occur. First, methods of bonding similar materials must be developed that are capable of being initiated autonomously. This process will lead to the development of a manual repair system for polyimide wire insulation. Second, ways to initiate these bonding methods that lead to materials that are similar to the primary insulation must be developed. Finally, steps one and two must be integrated to produce a material that has no residues from the process that degrades the insulating properties of the final repaired insulation. The self-healing technology, teamed with the ability to identify and locate damage, will greatly improve reliability and safety of electrical wiring of critical systems. This paper will address these topics, discuss the results of preliminary testing, and remaining development issues related to self-healing wire insulation.

Medelius, Petro↗

It’s Hip To Be Square - Refurbishment of the NASA Langley National Transonic Facility Test Section Plenum Door

The “nearside” plenum door (NPD) at the 39-year-old NASA Langley Research Center (LARC) National Transonic Facility (NTF) has become increasingly recalcitrant during the opening /closing sequence. The NPD is the primary means of entry into the test section for personnel and for model installation. The sliding NPD hardware guide bearings have failed three (3) times within a one-year period and “quick fixes” were able to be made to guide rails, wheels and bearings to put the NPD back into operation. The NPD no longer can utilize a “quick fix” as the rolling hardware is at its limit for further modifications. This presentation will describe the NPD situation, the findings as to the cause of the periodic NPD failures, and the solution to remove, refurbish, and reinstall the NPD.

Test Facilities↗

Launch Pad Flame Trench Refractory Materials

The launch complexes at NASA's John F. Kennedy Space Center (KSC) are critical support facilities for the successful launch of space-based vehicles. These facilities include a flame trench that bisects the pad at ground level. This trench includes a flame deflector system that consists of an inverted, V-shaped steel structure covered with a high temperature concrete material five inches thick that extends across the center of the flame trench. One side of the "V11 receives and deflects the flames from the orbiter main engines; the opposite side deflects the flames from the solid rocket boosters. There are also two movable deflectors at the top of the trench to provide additional protection to shuttle hardware from the solid rocket booster flames. These facilities are over 40 years old and are experiencing constant deterioration from launch heat/blast effects and environmental exposure. The refractory material currently used in launch pad flame deflectors has become susceptible to failure, resulting in large sections of the material breaking away from the steel base structure and creating high-speed projectiles during launch. These projectiles jeopardize the safety of the launch complex, crew, and vehicle. Post launch inspections have revealed that the number and frequency of repairs, as well as the area and size of the damage, is increasing with the number of launches. The Space Shuttle Program has accepted the extensive ground processing costs for post launch repair of damaged areas and investigations of future launch related failures for the remainder of the program. There currently are no long term solutions available for Constellation Program ground operations to address the poor performance and subsequent failures of the refractory materials. Over the last three years, significant liberation of refractory material in the flame trench and fire bricks along the adjacent trench walls following Space Shuttle launches have resulted in extensive investigations of failure mechanisms, load response, ejected material impact evaluation, and repair design analysis (environmental and structural assessment, induced environment from solid rocket booster plume, loads summary, and repair integrity), assessment of risk posture for flame trench debris, and justification of flight readiness rationale. Although the configuration of the launch pad, water and exhaust direction, and location of the Mobile Launcher Platform between the flame trench and the flight hardware should protect the Space Vehicle from debris exposure, loss of material could cause damage to a major element of the ground facility (resulting in temporary usage loss); and damage to other facility elements is possible. These are all significant risks that will impact ground operations for Constellation and development of new refractory material systems is necessary to reduce the likelihood of the foreign object debris hazard during launch. KSC is developing an alternate refractory material for the launch pad flame trench protection system, including flame deflector and flame trench walls, that will withstand launch conditions without the need for repair after every launch, as is currently the case. This paper will present a summary of the results from industry surveys, trade studies, life cycle cost analysis, and preliminary testing that have been performed to support and validate the development, testing, and qualification of new refractory materials.

Calle, Luz M.↗

The GSFC Combined Approach of ODC Stockpiling and Tribological Testing to Mitigate the Risks of ODC Elimination

In response to the elimination of production of several Ozone Depleting Chemicals (ODC's) which have been widely used in successful space flight mechanism cleaning and lubricating procedures, GSFC developed and implemented an overall philosophy of mitigating the risks to flight hardware during the transition phase to ODC-free cleaning procedures. The short term leg of the philosophy was the stockpiling of an appropriate amount of ODC solvents such that all short term GSFC missions will be able to stay with or revert to heritage cleaning and lubricating procedures in the face of life issues. The long-term leg of that philosophy was the initiation of a several tier testing program that will deliver increasing amounts of information over the next few years, starting with accelerated lubricant life tests that compare lubricant life on surfaces cleaned with ODC solvents with lubricant life on surfaces cleaned with ODC-free solvents. While tribological testing, mechanism life testing and space-flight experience will ultimately bring us into the 21st century with environmentally friendly means of cleaning long-life precision mechanism components, many satellites will be launched over the next few years before a number of important tribological questions can be answered. In order to prepare for this challenge, the Materials Engineering Branch in cooperation with the Electromechanical Branch launched an intensive review of all ongoing missions. The failure risk was determined for each long-life lubricated mechanism based on a number of parameters, including 4 comparison of flight solvents used to clean the heritage/life test hardware. Also studied was the ability of the mechanism manufacturers to stockpile ODC's based on state laws and company policies. A stockpiling strategy was constructed based on this information and subsequently implemented. This paper provides an overview of the GSFC ODC elimination risk mitigation philosophy as well as a detailed examination of the development of the ODC stockpiling plan.

Predmore, Roamer↗

International Space Station Common Cabin Air Assembly Water Separator On-Orbit Operation, Failure, and Redesign

The ability to control the temperature and humidity of an environment or habitat is critical for human survival. These factors are important to maintaining human health and comfort, as well as maintaining mechanical and electrical equipment in good working order to support the human and to accomplish mission objectives. The temperature and humidity of the International Space Station (ISS) United States On-orbit Segment (USOS) cabin air is controlled by the Common Cabin Air Assembly (CCAA). The CCAA consists of a fan, a condensing heat exchanger (CHX), an air/water separator, temperature and liquid sensors, and electrical controlling hardware and software. The Water Separator (WS) pulls in air and water from the CHX, and centrifugally separates the mixture, sending the water to the condensate bus and the air back into the CHX outlet airstream. Two distinct early failures of the CCAA Water Separator in the Quest Airlock forced operational changes and brought about the re-design of the Water Separator to improve the useful life via modification kits. The on-orbit operational environment of the Airlock presented challenges that were not foreseen with the original design of the Water Separator. Operational changes were instituted to prolong the life of the third installed WS, while waiting for newly designed Water Separators to be delivered on-orbit. The modification kit design involved several different components of the Water Separator, including the innovative use of a fabrication technique to build the impellers used in Water Separators out of titanium instead of aluminum. The technique allowed for the cost effective production of the low quantity build. This paper will describe the failures of the Water Separators in the Quest Airlock, the operational constraints that were implemented to prolong the life of the installed Water Separators throughout the USOS, and the innovative re-design of the CCAA Water Separator.

Balistreri, Steven F., Jr.↗

Robust Platinum Resistor Thermometer (PRT) Sensors and Reliable Bonding for Space Missions

Platinum resistance thermometers (PRTs) provide accurate temperature measurements over a wide temperature range and are used extensively on space missions due to their simplicity and linearity. A standard on spacecraft, PRTs are used to provide precision temperature control and vehicle health assessment. This paper reviews the extensive reliability testing of platinum resistor thermometer sensors (PRTs) and bonding methods used on the Mars Science Laboratory (MSL) mission and for the upcoming Soil Moisture Active Passive (SMAP) mission. During the Mars Exploration Rover (MER) mission, several key, JPL-packaged PRTs failed on those rovers prior to and within 1-Sol of landing due to thermally induced stresses. Similar failures can be traced back to other JPL missions dating back thirty years. As a result, MSL sought out a PRT more forgiving to the packaging configurations used at JPL, and extensively tested the Honeywell HRTS-5760-B-U-0-12 sensor to successfully demonstrate suitable robustness to thermal cycling. Specifically, this PRT was cycled 2,000 times, simulating three Martian winters and summers. The PRTs were bonded to six substrate materials (Aluminum 7050, treated Magnesium AZ231-B, Stainless Steel 304, Albemet, Titanium 6AL4V, and G-10), using four different aerospace adhesives--two epoxies and two silicones--that conformed to MSL's low out-gassing requirements. An additional epoxy was tested in a shorter environmental cycling test, when the need for a different temperature range adhesive was necessary for mobility and actuator hardware late in the fabrication process. All of this testing, along with electrostatic discharge (ESD) and destructive part analyses, demonstrate that this PRT is highly robust, and not subject to the failure of PRTs on previous missions. While there were two PRTs that failed during fabrication, to date there have been no in-flight PRT failures on MSL, including those on the Curiosity rover. Since MSL, the sensor has gone through a change in construction such that the manufacturer significantly restricts the minimum temperature. However, significant subsequent testing was performed with this new version of the part to show that it indeed is still robust to at least Mars minimum temperatures of -135(sup o)C. The additional completed testing will be described. This work has resulted in a successful sensor package qualification and a reliable bonding method suitable for use over large temperature extremes.

dectector↗

Robust Platinum Resistor Thermometer (PRT) Sensors and Reliable Bonding for Space Missions

Platinum resistance thermometers (PRTs) provide accurate temperature measurements over a wide temperature range and are used extensively on space missions due to their simplicity and linearity. A standard on spacecraft, PRTs are used to provide precision temperature control and vehicle health assessment. This paper reviews the extensive reliability testing of platinum resistor thermometer sensors (PRTs) and bonding methods used on the Mars Science Laboratory (MSL) mission and for the upcoming Soil Moisture Active Passive (SMAP) mission. During the Mars Exploration Rover (MER) mission, several key, JPL-packaged PRTs failed on those rovers prior to and within 1-Sol of landing due to thermally induced stresses. Similar failures can be traced back to other JPL missions dating back thirty years. As a result, MSL sought out a PRT more forgiving to the packaging configurations used at JPL, and extensively tested the Honeywell HRTS-5760-B-U-0-12 sensor to successfully demonstrate suitable robustness to thermal cycling. Specifically, this PRT was cycled 2,000 times, simulating three Martian winters and summers. The PRTs were bonded to six substrate materials (Aluminum 7050, treated Magnesium AZ231-B, Stainless Steel 304, Albemet, Titanium 6AL4V, and G-10), using four different aerospace adhesives--two epoxies and two silicones--that conformed to MSL's low out-gassing requirements. An additional epoxy was tested in a shorter environmental cycling test, when the need for a different temperature range adhesive was necessary for mobility and actuator hardware late in the fabrication process. All of this testing, along with electrostatic discharge (ESD) and destructive part analyses, demonstrate that this PRT is highly robust, and not subject to the failure of PRTs on previous missions. While there were two PRTs that failed during fabrication, to date there have been no in-flight PRT failures on MSL, including those on the Curiosity rover. Since MSL, the sensor has gone through a change in construction such that the manufacturer significantly restricts the minimum temperature. However, significant subsequent testing was performed with this new version of the part to show that it indeed is still robust to at least Mars minimum temperatures of -135 degrees Centigrade. The additional completed testing will be described. This work has resulted in a successful sensor package qualification and a reliable bonding method suitable for use over large temperature extremes

Platinum Resistor Thermometer (PRT)↗

Robotic and Human-Tended Collaborative Drilling Automation for Subsurface Exploration

Future in-situ lunar/martian resource utilization and characterization, as well as the scientific search for life on Mars, will require access to the subsurface and hence drilling. Drilling on Earth is hard - an art form more than an engineering discipline. Human operators listen and feel drill string vibrations coming from kilometers underground. Abundant mass and energy make it possible for terrestrial drilling to employ brute-force approaches to failure recovery and system performance issues. Space drilling will require intelligent and autonomous systems for robotic exploration and to support human exploration. Eventual in-situ resource utilization will require deep drilling with probable human-tended operation of large-bore drills, but initial lunar subsurface exploration and near-term ISRU will be accomplished with lightweight, rover-deployable or standalone drills capable of penetrating a few tens of meters in depth. These lightweight exploration drills have a direct counterpart in terrestrial prospecting and ore-body location, and will be designed to operate either human-tended or automated. NASA and industry now are acquiring experience in developing and building low-mass automated planetary prototype drills to design and build a pre-flight lunar prototype targeted for 2011-12 flight opportunities. A successful system will include development of drilling hardware, and automated control software to operate it safely and effectively. This includes control of the drilling hardware, state estimation of both the hardware and the lithography being drilled and state of the hole, and potentially planning and scheduling software suitable for uncertain situations such as drilling. Given that Humans on the Moon or Mars are unlikely to be able to spend protracted EVA periods at a drill site, both human-tended and robotic access to planetary subsurfaces will require some degree of standalone, autonomous drilling capability. Human-robotic coordination will be important, either between a robotic drill and humans on Earth, or a human-tended drill and its visiting crew. The Mars Analog Rio Tinto Experiment (MARTE) is a current project that studies and simulates the remote science operations between an automated drill in Spain and a distant, distributed human science team. The Drilling Automation for Mars Exploration (DAME) project, by contrast: is developing and testing standalone automation at a lunar/martian impact crater analog site in Arctic Canada. The drill hardware in both projects is a hardened, evolved version of the Advanced Deep Drill (ADD) developed by Honeybee Robotics for the Mars Subsurface Program. The current ADD is capable of 20m, and the DAME project is developing diagnostic and executive software for hands-off surface operations of the evolved version of this drill. The current drill automation architecture being developed by NASA and tested in 2004-06 at analog sites in the Arctic and Spain will add downhole diagnosis of different strata, bit wear detection, and dynamic replanning capabilities when unexpected failures or drilling conditions are discovered in conjunction with simulated mission operations and remote science planning. The most important determinant of future 1unar and martian drilling automation and staffing requirements will be the actual performance of automated prototype drilling hardware systems in field trials in simulated mission operations. It is difficult to accurately predict the level of automation and human interaction that will be needed for a lunar-deployed drill without first having extensive experience with the robotic control of prototype drill systems under realistic analog field conditions. Drill-specific failure modes and software design flaws will become most apparent at this stage. DAME will develop and test drill automation software and hardware under stressful operating conditions during several planned field campaigns. Initial results from summer 2004 tests show seven identifi distinct failure modes of the drill: cuttings-removal issues with low-power drilling into permafrost, and successful steps at executive control and initial automation.

Glass, Brian↗

Safety of spacecraft lightweight pressure vessels

With the advent of the age of flight and specifically space flight, a major effort was devoted to the development of lightweight metallic flight hardware. The paper deals with metallic pressure vessels designed to hold liquids or gases under pressure and with the methods for assuring safety through elimination of failures. The consequences of discontinuity stress failures range from leakage, bursting, and detrimental deformation to catastrophic failure, or literally, an explosion of the vessel. Controls, system design, protective devices and tests are discussed.

Bolger, P. H.↗

Digital Fly-By-Wire Flight Control Validation Experience

The experience gained in digital fly-by-wire technology through a flight test program being conducted by the NASA Dryden Flight Research Center in an F-8C aircraft is described. The system requirements are outlined, along with the requirements for flight qualification. The system is described, including the hardware components, the aircraft installation, and the system operation. The flight qualification experience is emphasized. The qualification process included the theoretical validation of the basic design, laboratory testing of the hardware and software elements, systems level testing, and flight testing. The most productive testing was performed on an iron bird aircraft, which used the actual electronic and hydraulic hardware and a simulation of the F-8 characteristics to provide the flight environment. The iron bird was used for sensor and system redundancy management testing, failure modes and effects testing, and stress testing in many cases with the pilot in the loop. The flight test program confirmed the quality of the validation process by achieving 50 flights without a known undetected failure and with no false alarms.

Szalai, K. J.↗

Safety considerations in the design and operation of large wind turbines

The engineering and safety techniques used to assure the reliable and safe operation of large wind turbine generators utilizing the Mod 2 Wind Turbine System Program as an example is described. The techniques involve a careful definition of the wind turbine's natural and operating environments, use of proven structural design criteria and analysis techniques, an evaluation of potential failure modes and hazards, and use of a fail safe and redundant component engineering philosophy. The role of an effective quality assurance program, tailored to specific hardware criticality, and the checkout and validation program developed to assure system integrity are described.

Reilly, D. H.↗