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At least 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Reliability and Maintainability Engineering - A Major Driver for Safety and Affordability

The United States National Aeronautics and Space Administration (NASA) is in the midst of an effort to design and build a safe and affordable heavy lift vehicle to go to the moon and beyond. To achieve that, NASA is seeking more innovative and efficient approaches to reduce cost while maintaining an acceptable level of safety and mission success. One area that has the potential to contribute significantly to achieving NASA safety and affordability goals is Reliability and Maintainability (R&M) engineering. Inadequate reliability or failure of critical safety items may directly jeopardize the safety of the user(s) and result in a loss of life. Inadequate reliability of equipment may directly jeopardize mission success. Systems designed to be more reliable (fewer failures) and maintainable (fewer resources needed) can lower the total life cycle cost. The Department of Defense (DOD) and industry experience has shown that optimized and adequate levels of R&M are critical for achieving a high level of safety and mission success, and low sustainment cost. Also, lessons learned from the Space Shuttle program clearly demonstrated the importance of R&M engineering in designing and operating safe and affordable launch systems. The Challenger and Columbia accidents are examples of the severe impact of design unreliability and process induced failures on system safety and mission success. These accidents demonstrated the criticality of reliability engineering in understanding component failure mechanisms and integrated system failures across the system elements interfaces. Experience from the shuttle program also shows that insufficient Reliability, Maintainability, and Supportability (RMS) engineering analyses upfront in the design phase can significantly increase the sustainment cost and, thereby, the total life cycle cost. Emphasis on RMS during the design phase is critical for identifying the design features and characteristics needed for time efficient processing, improved operational availability, and optimized maintenance and logistic support infrastructure. This paper discusses the role of R&M in a program acquisition phase and the potential impact of R&M on safety, mission success, operational availability, and affordability. This includes discussion of the R&M elements that need to be addressed and the R&M analyses that need to be performed in order to support a safe and affordable system design. The paper also provides some lessons learned from the Space Shuttle program on the impact of R&M on safety and affordability.

Safie, Fayssal M.↗
NASA NTRS2013

Robonaut 2 on the International Space Station: Status Update and Preparations for IVA Mobility

Robotics engineers, ground controllers and International Space Station (ISS) crew have been running successful experiments using Robonaut 2 (R2) on-board the ISS for more than a year. This humanoid upper body robot continues to expand its list of achievements and its capabilities to safely demonstrate maintenance and servicing tasks while working alongside human crewmembers. The next phase of the ISS R2 project will transition from a stationary Intra Vehicular Activity (IVA) upper body using a power/data umbilical, to an IVA mobile system with legs for repositioning, a battery backpack power supply, and wireless communications. These upgrades will enable the R2 team to evaluate hardware performance and to develop additional control algorithms and control verification techniques with R2 inside the ISS in preparation for the Extra Vehicular Activity (EVA) phase of R2 operations. As R2 becomes more capable in assisting with maintenance tasks, with minimal supervision, including repositioning itself to different work sites, the ISS crew will be burdened with fewer maintenance chores, leaving them more time to conduct other activities. R2's developers at the Johnson Space Center (JSC) are preparing the R2 IVA mobility hardware and software upgrades for delivery to the ISS in late 2013. This paper summarizes R2 ISS achievements to date, briefly describes the R2 IVA mobility upgrades, and discusses the R2 IVA mobility objectives and plans.

Ahlstrom, Thomas D.↗
NASA NTRS2014

Design Optimization of a Variable-Speed Power Turbine

NASA's Rotary Wing Project is investigating technologies that will enable the development of revolutionary civil tilt rotor aircraft. Previous studies have shown that for large tilt rotor aircraft to be viable, the rotor speeds need to be slowed significantly during the cruise portion of the flight. This requirement to slow the rotors during cruise presents an interesting challenge to the propulsion system designer as efficient engine performance must be achieved at two drastically different operating conditions. One potential solution to this challenge is to use a transmission with multiple gear ratios and shift to the appropriate ratio during flight. This solution will require a large transmission that is likely to be maintenance intensive and will require a complex shifting procedure to maintain power to the rotors at all times. An alternative solution is to use a fixed gear ratio transmission and require the power turbine to operate efficiently over the entire speed range. This concept is referred to as a variable-speed power-turbine (VSPT) and is the focus of the current study. This paper explores the design of a variable speed power turbine for civil tilt rotor applications using design optimization techniques applied to NASA's new meanline tool, the Object-Oriented Turbomachinery Analysis Code (OTAC).

design optimization↗
NASA NTRSDate not supplied

System Safety Analysis of Complex NASA Systems with Model-Based Engineering

The emergence of model-based engineering is transforming design and analysis methodologies [5]. A recognized benefit of model-based engineering is the existence of a “single source of truth” about the system that becomes the authoritative source of data and information for designers, analysts, and developers. This promotes consistency and efficiency as the design emerges and can be used to further optimize the design. Integrating System Safety Engineers to the “single source of truth” will ensure that the outputs of their assessments and analyses are relevant to the design as it evolves. Use of an integrated system model enables near immediate evaluation of a design change as well as development of operational processes for risk assessment and communication. Such models can enable efficient and timely analysis of system hazards (e.g., hazard fault tree analysis and procedure simulations) and produce complete, accurate, and more consistent products (e.g., hazard reports and safety requirement evaluations). Therefore, an agency-sponsored team at Goddard Space Flight Center (GSFC) recently completed a System Safety Study of modeling and testing capabilities as part of a Model-Based Safety and Mission Assurance Initiative (MBSMAI). Using an existing model developed for reliability analyses [1], GSFC modeling and system safety experts performed system safety analysis/modeling and produced safety products. The team evaluated model-based feasibility to support System Safety Engineering, developed safety analysis modeling processes, and identified tool capability advancement/development needs. These study results indicate model-based engineering is valid and useable for System

NASA↗
NASA NTRS1986

Presentation of Class 1 designs for a family of commuter airplanes

The Class 1 configuration designs of a family of commuter aircraft are presented. The proposed aircraft will have a capacity of from 25 to 100 passengers. They are to have the following common features: (1) 2 aft fuselage mounted engines; (2) a low wing; (3) a T-tail type empennage; and (4) a tricycle type landing gear. A family concept is introduced to achieve structural, systems and handling quality commonality throughout. Implementing commonality can substantially reduce manufacturing and production costs. By achieving common system designs, maintenance costs can be reduced by permitting airlines to stock a smaller inventory of spares. Therefore, the higher degree of commonality, the lower the direct operating and life cycle costs. The attempt to implement some of the commonality requirements has caused configuration design problems, i.e., the twin-body concept was introduced. Design data are compared to existing aircraft, and the extent of structural, systems and handling qualities achieved are reviewed.

Creighton, Tom↗
NASA NTRS1994

Optical surface contouring for non-destructive inspection of turbomachinery

Detection of stress cracks and other surface defects during maintenance and in-service inspection of propulsion system components, including turbine blades and combustion compartments, is presently performed visually. There is a need for a non-contact, miniaturized, and fully fieldable instrument that may be used as an automated inspection tool for inspection of aircraft engines. During this SBIR Phase 1 program, the feasibility of a ruggedized optical probe for automatic and nondestructive inspection of complex shaped objects will be established. Through a careful analysis of the measurement requirements, geometrical and optical constraints, and consideration of issues such as manufacturability, compactness, simplicity, and cost, one or more conceptual optical designs will be developed. The proposed concept will be further developed and a prototype will be fabricated during Phase 2.

Modarress, Dariush↗
NASA NTRS1993

Intelligent systems and advanced user interfaces for design, operation, and maintenance of command management systems

Historically, command management systems (CMS) have been large and expensive spacecraft-specific software systems that were costly to build, operate, and maintain. Current and emerging hardware, software, and user interface technologies may offer an opportunity to facilitate the initial formulation and design of a spacecraft-specific CMS as well as to develop a more generic CMS system. New technologies, in addition to a core CMS common to a range of spacecraft, may facilitate the training and enhance the efficiency of CMS operations. Current mission operations center (MOC) hardware and software include Unix workstations, the C/C++ programming languages, and an X window interface. This configuration provides the power and flexibility to support sophisticated and intelligent user interfaces that exploit state-of-the-art technologies in human-machine interaction, artificial intelligence, and software engineering. One of the goals of this research is to explore the extent to which technologies developed in the research laboratory can be productively applied in a complex system such as spacecraft command management. Initial examination of some of these issues in CMS design and operation suggests that application of technologies such as intelligent planning, case-based reasoning, human-machine systems design and analysis tools (e.g., operator and designer models), and human-computer interaction tools (e.g., graphics, visualization, and animation) may provide significant savings in the design, operation, and maintenance of the CMS for a specific spacecraft as well as continuity for CMS design and development across spacecraft. The first six months of this research saw a broad investigation by Georgia Tech researchers into the function, design, and operation of current and planned command management systems at Goddard Space Flight Center. As the first step, the researchers attempted to understand the current and anticipated horizons of command management systems at Goddard. Preliminary results are given on CMS commonalities and causes of low re-use, and methods are proposed to facilitate increased re-use.

Potter, William J.↗
NASA NTRS2016

Implementing Reliability Centered Maintenance (RCM) with State of the Art PT&I Technologies

Building on the work that was started two decades ago, Jacobs Space Operations Group has utilized state of the art PTI technologies to assess the current condition of the assets they manage under the Test and Operations Support Contract (TOSC). Specifically, the Asset Management department leveraged the benefits of ultrasound technology to quantify a motor issue in the Liquid Oxygen Storage Area, and troubleshoot the sources prior to loading the tank to perform Verification and Validation (VV) activities. This technology was efficient, easy to implement, and provided system engineers with data on a possible source of the problem. In situations where legacy motors are exhibiting unexpected noises, it may seem easier to remove and refurbish the motor and replace the bearings because that solution resolves most of the common causes of the noise. However, that solution would have involved additional spending and may not have solved issues stemming from the foundation, if those existed. By utilizing the ultrasound equipment provided by UE Systems, the sound profiles allowed Jacobs TOSC team to determine that the issue resembled a faulty bearing. After replacing the bearing, the unexpected noise ceased.

Reliability Centered Maintenance↗
NASA NTRS1989

Controlled environment crop production - Hydroponic vs. lunar regolith

The potential of controlled environment crop production in a lunar colony is discussed. Findings on the effects of optimal root-zone and aerial environments derived as part of the NASA CELSS project at Utah State are presented. The concept of growing wheat in optimal environment is discussed. It is suggested that genetic engineering might produce the ideal wheat cultivar for CELSS (about 100 mm in height with fewer leaves). The Utah State University hydroponic system is outlined and diagrams of the system and plant container construction are provided. Ratio of plant mass to solution mass, minimum root-zone volume, maintenance, and pH control are discussed. A comparison of liquid hydrophonic systems and lunar regoliths as substrates for plant growth is provided. The physiological processes that are affected by the root-zone environment are discussed including carbon partitioning, nutrient availability, nutrient absorption zones, root-zone oxygen, plant water potential, root-produced hormones, and rhizosphere pH control.

Bugbee, Bruce G.↗
NASA NTRS1993

Space Station technology testbed: 2010 deep space transport

A space station in a crew-tended or permanently crewed configuration will provide major R&D opportunities for innovative, technology and materials development and advanced space systems testing. A space station should be designed with the basic infrastructure elements required to grow into a major systems technology testbed. This space-based technology testbed can and should be used to support the development of technologies required to expand our utilization of near-Earth space, the Moon and the Earth-to-Jupiter region of the Solar System. Space station support of advanced technology and materials development will result in new techniques for high priority scientific research and the knowledge and R&D base needed for the development of major, new commercial product thrusts. To illustrate the technology testbed potential of a space station and to point the way to a bold, innovative approach to advanced space systems' development, a hypothetical deep space transport development and test plan is described. Key deep space transport R&D activities are described would lead to the readiness certification of an advanced, reusable interplanetary transport capable of supporting eight crewmembers or more. With the support of a focused and highly motivated, multi-agency ground R&D program, a deep space transport of this type could be assembled and tested by 2010. Key R&D activities on a space station would include: (1) experimental research investigating the microgravity assisted, restructuring of micro-engineered, materials (to develop and verify the in-space and in-situ 'tuning' of materials for use in debris and radiation shielding and other protective systems), (2) exposure of microengineered materials to the space environment for passive and operational performance tests (to develop in-situ maintenance and repair techniques and to support the development, enhancement, and implementation of protective systems, data and bio-processing systems, and virtual reality and telepresence/kinetic processes), (3) subsystem tests of advanced nuclear power, nuclear propulsion and communication systems (using boom extensions, remote station-keeping platforms and mobile EVA crew and robots), and (4) logistics support (crew and equipment) and command and control of deep space transport assembly, maintenance, and refueling (using a station-keeping platform).

Holt, Alan C.↗
NASA NTRS2002

Expedition 5 Crew Interviews: Peggy Whitson

Expedition 5 Flight Engineer Peggy Whitson is seen during a prelaunch interview. She gives details on the mission's goals and significance, her role in the mission, what her responsibilities will be, what the crew activities will be like (docking and undocking of two Progress unpiloted supply vehicles, normal space station maintenance tasks, conducting science experiments, installing the CETA (Crew and Equipment Translation) cart, and supporting the installation of the International Truss Structure S1 segment), the day-to-day life on an extended stay mission, the experiments she will be conducting on board, and what the S1 truss will mean to the International Space Station (ISS). Whitson ends with her thoughts on the short-term and long-term future of the ISS.

Source record↗
NASA NTRSDate not supplied

Short Circuiting the Controller – Missteps in Maintenance and Inspection of Process and Wiring in STS-93

The primary objective of the Space Transportation System mission 93 (STS-93) was to deploy the Chandra X-Ray Observatory. Chandra, the world's most powerful X-Ray telescope, allowed scientists from around the world to study some of the most distant and dynamic objects in the universe. Stripped of nearly 7,000 pounds of its own gear to make room for the payload, the orbiter assigned to this mission was Space Shuttle Columbia. Prior to STS-93, Columbia had flown 25 flights and was NASA's oldest and heaviest orbiter. On July 23, 1999, after two prior launch scrubs, Eileen Collins and her crew of four launched from Kennedy Space Center. About five seconds after launch, Mission Control at Johnson Space Center detected a voltage drop on one of Columbia's electrical buses. As a result of this power fluctuation, a primary and back-up Main Engine controller dropped offline. Given design redundancy, the two remaining controllers supported all three engines. If there had been any other AC bus issues, one engine of the three on the Orbiter would have shut down. The redundant set of digital computer units in each engine controller saved Columbia and her crew from a very risky contingency abort. Post-flight inspection revealed soot on a screw head and a hole in an adjacent Kapton insulated wire. The single strand of polyimide wire was located nearly half-way down the payload bay. The Shuttle Independent Assessment Team (SIAT) reported that the wire had rubbed and chaffed against a burred screw head. The burr was later determined to be the result of overtightening of the screw by a technician during a maintenance refurbishment. Alone, the burr may not have been problematic, but later, during another ground processing event, possibly years after, someone inadvertently stepped on the wiring harness. With the pressure and motion of unintended contact, some of the Kapton insulation rubbed off against the burred screw head. The SIAT suspected the wire damage was pre-existing and was caused 4 or 5 years prior to the flight. Finally, the intense vibrations during the launch sequence allowed contact between the exposed conductor and exposed metal area on the burred screw head, resulting in the arcing and shorting of the wire. Due to the quick turnaround times of Space Shuttle Orbiters, wiring issues caused from multiple maintenance events were often overlooked. Additionally, failing to incorporate thorough and early inclusion of human systems integration (HSI) applications as a crucial part of the decision process can result in these types of misshaps. In order to reduce human error associated with integrated manufacturing, maintenance, refurbishment and flight preparations, wire inspection criteria should be refined and standardized, visual inspection processes should be quantified, and technicians should be certified by specially trained instructors. This case, among many others, unveils why human error management and development of safety metrics is a vital piece in the development of complex systems, and why it should be supported aggressively and implemented program wide.

Human Systems Integration↗
NASA NTRS1973

Assuring reliability program effectiveness.

An attempt is made to provide simple identification and description of techniques that have proved to be most useful either in developing a new product or in improving reliability of an established product. The first reliability task is obtaining and organizing parts failure rate data. Other tasks are parts screening, tabulation of general failure rates, preventive maintenance, prediction of new product reliability, and statistical demonstration of achieved reliability. Five principal tasks for improving reliability involve the physics of failure research, derating of internal stresses, control of external stresses, functional redundancy, and failure effects control. A final task is the training and motivation of reliability specialist engineers.

Ball, L. W.↗
NASA NTRS1974

Flight test results of an automatic support system on board a YF-12A airplane

An automatic support system concept that isolated faults in an existing nonavionics subsystem was flight tested up to a Mach number of 3. The adaptation of the automated support concept to an existing system (the jet engine automatic inlet control system) caused most of the problems one would expect to encounter in other applications. These problems and their solutions are discussed. Criteria for integrating automatic support into the initial design of new subsystems are included in the paper. Cost effectiveness resulted from both the low maintenance of the automated system and the man-hour saving resulting from the real time diagnosis of the monitored subsystem.

Love, J. E.↗
NASA NTRS1991

The Guardian: Preliminary design of a close air support aircraft

One design is presented of a Close Air Support (CAS) aircraft. It is a canard wing, twin engine, twin vertical tail aircraft that has the capability to cruise at 520 knots. The Guardian contains state of the art flight control systems. Specific highlights of the Guardian include: (1) low cost (the acquisition cost per airplane is $13.6 million for a production of 500 airplanes); (2) low maintenance (it was designed to be easily maintainable in unprepared fields); and (3) high versatility (it can perform a wide range of missions). Along with being a CAS aircraft, it is capable of long ferry missions, battlefield interdiction, maritime attack, and combat rescue. The Guardian is capable of a maximum ferry of 3800 nm, can takeoff in a distance of 1700 ft, land in a ground roll distance of 1644 ft. It has a maximum takeoff weight of 48,753 lbs, and is capable of carrying up to 19,500 lbs of ordinance.

Haag, Jonathan↗
NASA NTRS2009

Windage Power Loss in Gas Foil Bearings and the Rotor-Stator Clearance of High Speed Generators Operating in High Pressure Environments

Closed Brayton Cycle (CBC) and Closed Supercritical Cycle (CSC) engines are prime candidates to convert heat from a reactor into electric power for robotic space exploration and habitation. These engine concepts incorporate a permanent magnet starter/generator mounted on the engine shaft along with the requisite turbomachinery. Successful completion of the long-duration missions currently anticipated for these engines will require designs that adequately address all losses within the machine. The preliminary thermal management concept for these engine types is to use the cycle working fluid to provide the required cooling. In addition to providing cooling, the working fluid will also serve as the bearing lubricant. Additional requirements, due to the unique application of these microturbines, are zero contamination of the working fluid and entirely maintenance-free operation for many years. Losses in the gas foil bearings and within the rotor-stator gap of the generator become increasingly important as both rotational speed and mean operating pressure are increased. This paper presents the results of an experimental study, which obtained direct torque measurements on gas foil bearings and generator rotor-stator gaps. Test conditions for these measurements included rotational speeds up to 42,000 revolutions per minute, pressures up to 45 atmospheres, and test gases of nitrogen, helium, and carbon dioxide. These conditions provided a maximum test Taylor number of nearly one million. The results show an exponential rise in power loss as mean operating density is increased for both the gas foil bearing and generator windage. These typical "secondary" losses can become larger than the total system output power if conventional design paradigms are followed. A nondimensional analysis is presented to extend the experimental results into the CSC range for the generator windage.

Bruckner, Robert J.↗
NASA NTRS2013

Model-Based Diagnosis and Prognosis of a Water Recycling System

A water recycling system (WRS) deployed at NASA Ames Research Center s Sustainability Base (an energy efficient office building that integrates some novel technologies developed for space applications) will serve as a testbed for long duration testing of next generation spacecraft water recycling systems for future human spaceflight missions. This system cleans graywater (waste water collected from sinks and showers) and recycles it into clean water. Like all engineered systems, the WRS is prone to standard degradation due to regular use, as well as other faults. Diagnostic and prognostic applications will be deployed on the WRS to ensure its safe, efficient, and correct operation. The diagnostic and prognostic results can be used to enable condition-based maintenance to avoid unplanned outages, and perhaps extend the useful life of the WRS. Diagnosis involves detecting when a fault occurs, isolating the root cause of the fault, and identifying the extent of damage. Prognosis involves predicting when the system will reach its end of life irrespective of whether an abnormal condition is present or not. In this paper, first, we develop a physics model of both nominal and faulty system behavior of the WRS. Then, we apply an integrated model-based diagnosis and prognosis framework to the simulation model of the WRS for several different fault scenarios to detect, isolate, and identify faults, and predict the end of life in each fault scenario, and present the experimental results.

Roychoudhury, Indranil↗
NASA NTRS1994

Cabin fuselage structural design with engine installation and control system

Design requirements for the cabin, cabin system, flight controls, engine installation, and wing-fuselage interface that provide adequate interior volume for occupant seating, cabin ingress and egress, and safety are presented. The fuselage structure must be sufficient to meet the loadings specified in the appropriate sections of Federal Aviation Regulation Part 23. The critical structure must provide a safe life of 10(exp 6) load cycles and 10,000 operational mission cycles. The cabin seating and controls must provide adjustment to account for various pilot physiques and to aid in maintenance and operation of the aircraft. Seats and doors shall not bind or lockup under normal operation. Cabin systems such as heating and ventilation, electrical, lighting, intercom, and avionics must be included in the design. The control system will consist of ailerons, elevator, and rudders. The system must provide required deflections with a combination of push rods, bell cranks, pulleys, and linkages. The system will be free from slack and provide smooth operation without binding. Environmental considerations include variations in temperature and atmospheric pressure, protection against sand, dust, rain, humidity, ice, snow, salt/fog atmosphere, wind and gusts, and shock and vibration. The following design goals were set to meet the requirements of the statement of work: safety, performance, manufacturing and cost. To prevent the engine from penetrating the passenger area in the event of a crash was the primary safety concern. Weight and the fuselage aerodynamics were the primary performance concerns. Commonality and ease of manufacturing were major considerations to reduce cost.

Balakrishnan, Tanapaal↗