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Spaceflight Ground Support Equipment Reliability & System Safety Data

Presented were Reliability Analysis, consisting primarily of Failure Modes and Effects Analysis (FMEA), and System Safety Analysis, consisting of Preliminary Hazards Analysis (PHA), performed to ensure that the CoNNeCT (Communications, Navigation, and Networking re- Configurable Testbed) Flight System was safely and reliably operated during its Assembly, Integration and Test (AI&T) phase. A tailored approach to the NASA Ground Support Equipment (GSE) standard, NASA-STD-5005C, involving the application of the appropriate Requirements, S&MA discipline expertise, and a Configuration Management system (to retain a record of the analysis and documentation) were presented. Presented were System Block Diagrams of selected GSE and the corresponding FMEA, as well as the PHAs. Also discussed are the specific examples of the FMEAs and PHAs being used during the AI&T phase to drive modifications to the GSE (via "redlining" of test procedures, and the placement of warning stickers to protect the flight hardware) before being interfaced to the Flight System. These modifications were necessary because failure modes and hazards were identified during the analysis that had not been properly mitigated. Strict Configuration Management was applied to changes (whether due to upgrades or expired calibrations) in the GSE by revisiting the FMEAs and PHAs to reflect the latest System Block Diagrams and Bill Of Material. The CoNNeCT flight system has been successfully assembled, integrated, tested, and shipped to the launch site without incident. This demonstrates that the steps taken to safeguard the flight system when it was interfaced to the various GSE were successful.

Fernandez, Rene↗

Characterization of a Regenerable Impactor Filter for Spacecraft Cabin Applications

Regenerable filters will play an important role in human exploration beyond low-Earth orbit. Life Support Systems aboard crewed spacecrafts will have to operate reliably and with little maintenance over periods of more than a year, even multiple years. Air filters are a key component of spacecraft life support systems, but they often require frequent routine maintenance. Bacterial filters aboard the International Space Station require almost weekly cleaning of the pre-filter screen to remove large lint debris captured in the microgravity environment. The source of the airborne matter which is collected on the filter screen is typically from clothing fibers, biological matter (hair, skin, nails, etc.) and material wear. Clearly a need for low maintenance filters requiring little to no crew intervention will be vital to the success of the mission. An impactor filter is being developed and tested to address this need. This filter captures large particle matter through inertial separation and impaction methods on collection surfaces, which can be automatically cleaned after they become heavily loaded. The impactor filter can serve as a pre-filter to augment the life of higher efficiency filters that capture fine and ultrafine particles. A prototype of the filter is being tested at the Particulate Filtration Laboratory at NASA Glenn Research Center to determine performance characteristics, including particle cut size and overall efficiency. Model results are presented for the flow characteristics near the orifice plate through which the particle-laden flow is accelerated as well as around the collection bands.

air filters↗

Limb Correction of Infrared Imagery in Cloudy Regions for the Improved Interpretation of RGB Composites

Red-Green-Blue (RGB) composites (EUMETSAT User Services 2009) combine information from several channels into a single composite image. RGB composites contain the same information as the original channels, but presents the information in a more efficient manner. However, RGB composites derived from infrared imagery of both polar-orbiting and geostationary sensors are adversely affected by the limb effect, which interferes with the qualitative interpretation of RGB composites at large viewing zenith angles. The limb effect, or limb-cooling, is a result of an increase in optical path length of the absorbing atmosphere as viewing zenith angle increases (Goldberg et al. 2001; Joyce et al. 2001; Liu and Weng 2007). As a result, greater atmospheric absorption occurs at the limb, causing the sensor to observe anomalously cooler brightness temperatures. Figure 1 illustrates this effect. In general, limb-cooling results in a 4-11 K decrease in measured brightness temperature (Liu and Weng 2007) depending on the infrared band. For example, water vapor and ozone absorption channels display much larger limb-cooling than infrared window channels. Consequently, RGB composites created from infrared imagery not corrected for limb effects can only be reliably interpreted close to nadir, which reduces the spatial coverage of the available imagery. Elmer (2015) developed a reliable, operational limb correction technique for clear regions. However, many RGB composites are intended to be used and interpreted in cloudy regions, so a limb correction methodology valid for both clear and cloudy regions is needed. This paper presents a limb correction technique valid for both clear and cloudy regions, which is described in Section 2. Section 3 presents several RGB case studies demonstrating the improved functionality of limb-corrected RGBs in both clear and cloudy regions, and Section 4 summarizes and presents the key conclusions of this work.

RGB↗

Integrated Human-in-the-Loop Ground Testing - Value, History, and the Future

Systems for very long-duration human missions to Mars will be designed to operate reliably for many years and many of these systems will never be returned to Earth. The need for high reliability is driven by the requirement for safe functioning of remote, long-duration crewed systems and also by unsympathetic abort scenarios. Abort from a Mars mission could be as long as 450 days to return to Earth. The key to developing a human-in-the-loop architecture is a development process that allows for a logical sequence of validating successful development in a stepwise manner, with assessment of key performance parameters (KPPs) at each step; especially important are KPPs for technologies evaluated in a full systems context with human crews on Earth and on space platforms such as the ISS. This presentation will explore the implications of such an approach to technology development and validation including the roles of ground and space-based testing necessary to develop a highly reliable system for long duration human exploration missions. Historical development and systems testing from Mercury to the International Space Station (ISS) to ground testing will be reviewed. Current work as well as recommendations for future work will be described.

Henninger, Donald L.↗

Isokinetic TWC Evaporator Probe: Calculations and Systemic Uncertainty Analysis

A new Isokinetic Total Water Content Evaporator (IKP2) was downsized from a prototype instrument, specifically to make airborne measurements of hydrometeor total water content (TWC) in deep tropical convective clouds to assess the new ice crystal Appendix D icing envelope. The probe underwent numerous laboratory and wind tunnel investigations to ensure reliable operation under the difficult high altitude/speed/TWC conditions under which other TWC instruments have been known to either fail, or have unknown performance characteristics and the results are presented in a companion paper (Ref. 1). This paper presents the equations used to determine the total water content (TWC) of the sampled atmosphere from the values measured by the IKP2 or necessary ancillary data from other instruments. The uncertainty in the final TWC is determined by propagating the uncertainty in the measured values through the calculations to the final result. Two techniques were used and the results compared. The first is a typical analytical method of propagating uncertainty and the second performs a Monte Carlo simulation. The results are very similar with differences that are insignificant for practical purposes. The uncertainty is between 2 and 3 percent at most practical operating conditions. The capture efficiency of the IKP2 was also examined based on a computational fluid dynamic simulation of the original IKP and scaled down to the IKP2. Particles above 24 micrometers were found to have a capture efficiency greater than 99 percent at all operating conditions.

Meteorological Instrument↗

Isokinetic TWC Evaporator Probe: Development of the IKP2 and Performance Testing for the HAIC-HIWC Darwin 2014 and Cayenne-2015 Field Campaigns

A new Isokinetic Total Water Content Evaporator (IKP2) was downsized from a prototype instrument, specifically to make airborne measurements of hydrometeor total water content (TWC) in deep tropical convective clouds to assess the new ice crystal Appendix D icing envelope. The probe underwent numerous laboratory and wind tunnel investigations to ensure reliable operation under the difficult high altitude/speed/TWC conditions under which other TWC instruments have been known to either fail, or have unknown performance characteristics. The article tracks the testing and modifications of the IKP2 probe to ensure its readiness for three flight campaigns in 2014 and 2015. Comparisons are made between the IKP2 and the NASA Icing Research Tunnel reference values in liquid conditions, and to an exploratory technique estimating ice water content from a bulk ice capture cylinder method in glaciated conditions. These comparisons suggest that the initial target of 20 percent accuracy in TWC has been achieved and likely exceeded for tested TWC values in excess of about 0.5 gm (exp -3). Uncertainties in the ice water content reference method have been identified. Complications are introduced in the necessary subtraction of an independently measured background water vapour concentration, errors of which are small at the colder flight temperatures, but increase rapidly with increasing temperature, and ultimately limit the practical use of the instrument in a tropical convective atmosphere to conditions colder than about 0 degrees C. A companion article in this conference traces the accuracy of the components of the IKP2 to derive estimated system accuracy.

Meteorological Instruments↗

Isokinetic TWC Evaporator Probe: Calculations and Systemic Uncertainty Analysis

A new Isokinetic Total Water Content Evaporator (IKP2) was downsized from a prototype instrument, specifically to make airborne measurements of hydrometeor total water content (TWC) in deep tropical convective clouds to assess the new ice crystal Appendix D icing envelope. The probe underwent numerous laboratory and wind tunnel investigations to ensure reliable operation under the difficult high altitude/speed/TWC conditions under which other TWC instruments have been known to either fail, or have unknown performance characteristics and the results are presented in a companion paper. This paper presents the equations used to determine the total water content (TWC) of the sampled atmosphere from the values measured by the IKP2 or necessary ancillary data from other instruments. The uncertainty in the final TWC is determined by propagating the uncertainty in the measured values through the calculations to the final result. Two techniques were used and the results compared. The first is a typical analytical method of propagating uncertainty and the second performs a Monte Carlo simulation. The results are very similar with differences that are insignificant for practical purposes. The uncertainty is between 2 percent and 3 percent at most practical operating conditions. The capture efficiency of the IKP2 was also examined based on a computational fluid dynamic simulation of the original IKP and scaled down to the IKP2. Particles above 24 microns were found to have a capture efficiency greater than 99 percent at all operating conditions.

Aircraft Icing↗

Isokinetic TWC Evaporator Probe: Development of the IKP2 and Performance Testing for the HAIC-HIWC Darwin 2014 and Cayenne 2015 Field Campaigns

A new Isokinetic Total Water Content Evaporator (IKP2) was downsized from a prototype instrument, specifically to make airborne measurements of hydrometeor total water content (TWC) in deep tropical convective clouds to assess the new ice crystal Appendix D icing envelope. The probe underwent numerous laboratory and wind tunnel investigations to ensure reliable operation under the difficult high altitude/speed/TWC conditions under which other TWC instruments have been known to either fail, or have unknown performance characteristics. The article tracks the testing and modifications of the IKP2 probe to ensure its readiness for three flight campaigns in 2014 and 2015. Comparisons are made between the IKP2 and the NASA Icing Research Tunnel reference values in liquid conditions, and to an exploratory technique estimating ice water content from a bulk ice capture cylinder method in glaciated conditions. These comparisons suggest that the initial target of 20% accuracy in TWC has been achieved and likely exceeded for tested TWC values in excess of about 0.5/cu gm. Uncertainties in the ice water content reference method have been identified. Complications are introduced in the necessary subtraction of an independently measured background water vapor concentration, errors of which are small at the colder flight temperatures, but increase rapidly with increasing temperature, and ultimately limit the practical use of the instrument in a tropical convective atmosphere to conditions colder than about 0 C. A companion article in this conference traces the accuracy of the components of the IKP2 to derive estimated system accuracy.

Meteorological Instruments↗

Packaged Capacitive Pressure Sensor System for Aircraft Engine Health Monitoring

This paper describes the development of a packaged silicon carbide (SiC) based MEMS pressure sensor system designed specifically for a conventional turbofan engine. The electronic circuit is based on a Clapp-type oscillator that incorporates a 6H-SiC MESFET, a SiCN MEMS capacitive pressure sensor, titanate MIM capacitors, wirewound inductors, and thick film resistors. The pressure sensor serves as the capacitor in the LC tank circuit, thereby linking pressure to the resonant frequency of the oscillator. The oscillator and DC bias circuitry were fabricated on an alumina substrate and secured inside a metal housing. The packaged sensing system reliably operates at 0 to 350 psi and 25 to 540C. The system has a pressure sensitivity of 6.8 x 10E-2 MHzpsi. The packaged system shows negligible difference in frequency response between 25 and 400C. The fully packaged sensor passed standard benchtop acceptance tests and was evaluated on a flight-worthy engine.

Harsh environment↗

Automated Commanding of the SMAP Spacecraft Enables Efficient, Reliable, and Responsive Operations

The Soil Moisture Active Passive (SMAP) mission developed and deployed a system to autonomously handle most routine commanding of the observatory. This system of ground software is able to build commands, validate them, and radiate the commands to the spacecraft, all without human interaction. In the case of an off -nominal scenario, the system will abort gracefully and notify the mission operations team of the problem. The system was phased into operations during the first three months of the SMAP mission and handles over 90% of the weekly commanding of the vehicle. The gradual introduction of the automation in flight, along with an extensive test campaign, was instrumental in the success of the software. The automation has enabled substantial efficiencies in operations team staffing and has improved reliability by removing the potential for human error. The system also allows the SMAP project to be more responsive which has shown significant benefits in areas of data latency and science accuracy.

automation↗

Extreme Temperature Performance of Automotive-Grade Small Signal Bipolar Junction Transistors

Electronics designed for space exploration missions must display efficient and reliable operation under extreme temperature conditions. For example, lunar outposts, Mars rovers and landers, James Webb Space Telescope, Europa orbiter, and deep space probes represent examples of missions where extreme temperatures and thermal cycling are encountered. Switching transistors, small signal as well as power level devices, are widely used in electronic controllers, data instrumentation, and power management and distribution systems. Little is known, however, about their performance in extreme temperature environments beyond their specified operating range; in particular under cryogenic conditions. This report summarizes preliminary results obtained on the evaluation of commercial-off-the-shelf (COTS) automotive-grade NPN small signal transistors over a wide temperature range and thermal cycling. The investigations were carried out to establish a baseline on functionality of these transistors and to determine suitability for use outside their recommended temperature limits.

Thermal Cycling↗

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall inform future iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300degC over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall inform future iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300 C over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hour hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall informfuture iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300 degrees C over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hour durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser low-power, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA's Science Technology Mission Directorate (STMD).

Benavides, Gabriel F.↗

Serious Gaming for Building a Basis of Certification via Trust and Trustworthiness of Autonomous Systems

Autonomous systems governed by a variety of adaptive and nondeterministic algorithms are being planned for inclusion into safety-critical environments, such as unmanned aircraft and space systems in both civilian and military applications. However, until autonomous systems are proven and perceived to be capable and resilient in the face of unanticipated conditions, humans will be reluctant or unable to delegate authority, remaining in control aided by machine-based information and decision support. Proving capability, or trustworthiness, is a necessary component of certification. Perceived capability is a component of trust. Trustworthiness is an attribute of a cyber-physical system that requires context-driven metrics to prove and certify. Trust is an attribute of the agents participating in the system and is gained over time and multiple interactions through trustworthy behavior and transparency. Historically, artificial intelligence and machine learning systems provide answers without explanation - without a rationale or insight into the machine “thinking”. In order to function as trusted teammates, machines must be able to explain their decisions and actions. This transparency is a product of both content and communication. NASA’s Autonomy Teaming & TRAjectories for Complex Trusted Operational Reliability (ATTRACTOR) project seeks to build a basis for certification of autonomous systems via establishing metrics for trustworthiness and trust in multi-agent team interactions, using AI (Artificial Intelligence) explainability and persistent modeling and simulation, in the context of mission planning and execution, with analyzable trajectories. Inspired by Massively Multiplayer Online Role Playing Games (MMORPG) and Serious Gaming, the proposed ATTRACTOR modeling and simulation environment is similar to online gaming environments in which player (aka agent) participants interact with each other, affect their environment, and expect the simulation to persist and change regardless of any individual agent’s active participation. This persistent simulation environment will accommodate individual agents, groups of self-organizing agents, and large-scale infrastructure behavior. The effects of the emerging adaptation and coevolution can be observed and measured to building a basis of measurable trustworthiness and trust, toward certification of safety-critical autonomous systems.

Allen, B. Danette↗

ICAROUS Simulation Video for AUVSI XPONENTIAL 2019

Video demonstrate the ability of ICAROUS (Independent Configurable Architecture for Reliable Operations of Autonomous Systems) to perform autonomous traffic avoidance and merging with cooperative aircraft in simulation. The Video will be shown in the NASA booth at AUVSI XPONENTIAL (Chicago, IL 4/29/19-5 /2/19) to aid in demonstrating and explaining the capabilities of the ICAROUS research system.

Malekpour, Mahyar R↗

Magnetic Levitation for Long-Life Space Mechanisms: Technology Assessment and Remaining Challenges

Spacecraft mechanisms and mechanical systems must operate reliably and without failure to enable successful, long-term space missions. Such requirements place demands upon the tribological elements, especially bearings, which are frequently difficult or impossible to satisfy. Several recent, high-profile bearing failures in coolant fluid pumps and attitude control system (ACS) momentum wheels provided the impetus to assess the state-of-the-art non-contacting magnetic levitation-based, rotor support technologies.Magnetic levitation technology continues to gain acceptance for terrestrial applications and has been spaceflight demonstrated in mechanical systems such as reaction wheels (RWs) but is not in widespread use. The specific reasons inhibiting this new technology are not readily clear but include cost, weight, performance, and perceived risk. These reasons arise from a variety of real and perceived technical limitations in areas like materials, controls, sensors, thermal management and others. This white paper seeks to determine, define, and quantify the technical hurdles and gaps that must be overcome to enable the broad adoption of non-contacting bearings for long-life space mechanisms. It is anticipated that a better understanding of this complex topic may guide resource investments and clear the path to improved performance mechanical systems for spacecraft.

Samuel A Howard↗

Towards Explainability of UAV-Based Convolutional Neural Networks for Object Classification

f autonomous systems using trust and trustworthiness is the focus of Autonomy Teaming and TRAjectories for Complex Trusted Operational Reliability (ATTRACTOR), a new NASA Convergent Aeronautical Solutions (CAS) Project. One critical research element of ATTRACTOR is explainability of the decision-making across relevant subsystems of an autonomous system. The ability to explain why an autonomous system makes a decision is needed to establish a basis of trustworthiness to safely complete a mission. Convolutional Neural Networks (CNNs) are popular visual object classifiers that have achieved high levels of classification performances without clear insight into the mechanisms of the internal layers and features. To explore the explainability of the internal components of CNNs, we reviewed three feature visualization methods in a layer-by-layer approach using aviation related images as inputs. Our approach to this is to analyze the key components of a classification event in order to generate component labels for features of the classified image at different layers of depths. For example, an airplane has wings, engines, and landing gear. These could possibly be identified somewhere in the hidden layers from the classification and these descriptive labels could be provided to a human or machine teammate while conducting a shared mission and to engender trust. Each descriptive feature may also be decomposed to a combination of primitives such as shapes and lines. We expect that knowing the combination of shapes and parts that create a classification will enable trust in the system and insight into creating better structures for the CNN.

Dolph, Chester V.↗