Results for “reliability methodologies” — Page 39

NASA NTRS2008

Structural Benchmark Creep Testing for the Advanced Stirling Convertor Heater Head

The National Aeronautics and Space Administration (NASA) has identified the high efficiency Advanced Stirling Radioisotope Generator (ASRG) as a candidate power source for use on long duration Science missions such as lunar applications, Mars rovers, and deep space missions. For the inherent long life times required, a structurally significant design limit for the heater head component of the ASRG Advanced Stirling Convertor (ASC) is creep deformation induced at low stress levels and high temperatures. Demonstrating proof of adequate margins on creep deformation and rupture for the operating conditions and the MarM-247 material of construction is a challenge that the NASA Glenn Research Center is addressing. The combined analytical and experimental program ensures integrity and high reliability of the heater head for its 17-year design life. The life assessment approach starts with an extensive series of uniaxial creep tests on thin MarM-247 specimens that comprise the same chemistry, microstructure, and heat treatment processing as the heater head itself. This effort addresses a scarcity of openly available creep properties for the material as well as for the virtual absence of understanding of the effect on creep properties due to very thin walls, fine grains, low stress levels, and high-temperature fabrication steps. The approach continues with a considerable analytical effort, both deterministically to evaluate the median creep life using nonlinear finite element analysis, and probabilistically to calculate the heater head s reliability to a higher degree. Finally, the approach includes a substantial structural benchmark creep testing activity to calibrate and validate the analytical work. This last element provides high fidelity testing of prototypical heater head test articles; the testing includes the relevant material issues and the essential multiaxial stress state, and applies prototypical and accelerated temperature profiles for timely results in a highly controlled laboratory environment. This paper focuses on the last element and presents a preliminary methodology for creep rate prediction, the experimental methods, test challenges, and results from benchmark testing of a trial MarM-247 heater head test article. The results compare favorably with the analytical strain predictions. A description of other test findings is provided, and recommendations for future test procedures are suggested. The manuscript concludes with describing the potential impact of the heater head creep life assessment and benchmark testing effort on the ASC program.

Krause, David L.↗

NASA NTRS1994

Fatigue reliability method with in-service inspections

The first reliability method (FORM) has traditionally been applied in a fatigue reliability setting to one inspection interval at a time, so that the random distribution of crack lengths must be recharacterized following each inspection. The FORM presented here allow each analysis to span several inspection periods without explicit characterization of the crack length distribution upon each inspection. The method thereby preserves the attractive feature of FORM in that relatively few realizations in the random variable space need to be considered. Examples are given which show that the present methodology gives estimates which are in good agreement with Monte Carlo simulations and is efficient even for complex components.

Harkness, H. H.↗

NASA NTRS2003

Use of Soft Computing Technologies For Rocket Engine Control

The problem to be addressed in this paper is to explore how the use of Soft Computing Technologies (SCT) could be employed to further improve overall engine system reliability and performance. Specifically, this will be presented by enhancing rocket engine control and engine health management (EHM) using SCT coupled with conventional control technologies, and sound software engineering practices used in Marshall s Flight Software Group. The principle goals are to improve software management, software development time and maintenance, processor execution, fault tolerance and mitigation, and nonlinear control in power level transitions. The intent is not to discuss any shortcomings of existing engine control and EHM methodologies, but to provide alternative design choices for control, EHM, implementation, performance, and sustaining engineering. The approaches outlined in this paper will require knowledge in the fields of rocket engine propulsion, software engineering for embedded systems, and soft computing technologies (i.e., neural networks, fuzzy logic, and Bayesian belief networks), much of which is presented in this paper. The first targeted demonstration rocket engine platform is the MC-1 (formerly FASTRAC Engine) which is simulated with hardware and software in the Marshall Avionics & Software Testbed laboratory that

Trevino, Luis C.↗

NASA NTRS2003

Development of Testing Methodologies for the Mechanical Properties of MEMS

This effort is to investigate and design testing strategies to determine the mechanical properties of MicroElectroMechanical Systems (MEMS) as well as investigate the development of a MEMS Probabilistic Design Methodology (PDM). One item of potential interest is the design of a test for the Weibull size effect in pressure membranes. The Weibull size effect is a consequence of a stochastic strength response predicted from the Weibull distribution. Confirming that MEMS strength is controlled by the Weibull distribution will enable the development of a probabilistic design methodology for MEMS - similar to the GRC developed CARES/Life program for bulk ceramics. However, the primary area of investigation will most likely be analysis and modeling of material interfaces for strength as well as developing a strategy to handle stress singularities at sharp corners, filets, and material interfaces. This will be a continuation of the previous years work. The ultimate objective of this effort is to further develop and verify the ability of the Ceramics Analysis and Reliability Evaluation of Structures Life (CARES/Life) code to predict the time-dependent reliability of MEMS structures subjected to multiple transient loads.

Ekwaro-Osire, Stephen↗

NASA NTRS2004

Research Performed within the Non-Destructive Evaluation Team at NASA Glenn Research Center

Non-destructive testing is essential in many fields of manufacturing and research in order to perform reliable examination of potentially damaged materials and parts without destroying the inherent structure of the materials. Thus, the Non-Destructive Evaluation (NDE) Team at NASA Glenn Research Center partakes in various projects to improve materials testing equipment as well as analyze materials, material defects, and material deficiencies. Due to the array of projects within the NDE Team at this time, five research aims were supplemental to some current projects. A literature survey of "DE and testing methodologies as related to rocks was performed. Also, Mars Expedition Rover technology was assessed to understand the requirements for instrumentation in harsh space environments (e.g. temperature). Potential instrumentation and technologies were also considered and documented. The literature survey provided background and potential sources for a proposal to acquire funding for ultrasonic instrumentation on board a future Mars expedition. The laboratory uses a Santec Systems AcousticScope AS200 acoustography system. Labview code was written within the current program in order to improve the current performance of the acoustography system. A sample of Reinforced Carbon/Carbon (RCC) material from the leading edge of the space shuttle underwent various non-destructive tests (guided wave scanning, thermography, computed tomography, real time x-ray, etc.) in order to characterize its structure and examine possible defects. Guided wave scan data of a ceramic matrix composite (CMC) panel was reanalyzed utilizing image correlations and signal processing variables. Additional guided wave scans and thermography were also performed on the CMC panel. These reevaluated data and images will be used in future presentations and publications. An additional axis for the guided wave scanner was designed, constructed, and implemented. This additional axis allowed incremental spacing of the previously fixed transducers for ultrasonic velocity measurements.

Burns, Erin A.↗

NASA NTRS2012

Challenges of Sustaining the International Space Station through 2020 and Beyond: Including Epistemic Uncertainty in Reassessing Confidence Targets

This paper introduces an analytical approach, Probability and Confidence Trade-space (PACT), which can be used to assess uncertainty in International Space Station (ISS) hardware sparing necessary to extend the life of the vehicle. There are several key areas under consideration in this research. We investigate what sparing confidence targets may be reasonable to ensure vehicle survivability and for completion of science on the ISS. The results of the analysis will provide a methodological basis for reassessing vehicle subsystem confidence targets. An ongoing annual analysis currently compares the probability of existing spares exceeding the total expected unit demand of the Orbital Replacement Unit (ORU) in functional hierarchies approximating the vehicle subsystems. In cases where the functional hierarchies availability does not meet subsystem confidence targets, the current sparing analysis further identifies which ORUs may require additional spares to extend the life of the ISS. The resulting probability is dependent upon hardware reliability estimates. However, the ISS hardware fleet carries considerable epistemic uncertainty (uncertainty in the knowledge of the true hardware failure rate), which does not currently factor into the annual sparing analysis. The existing confidence targets may be conservative. This paper will also discuss how confidence targets may be relaxed based on the inclusion of epistemic uncertainty for each ORU. The paper will conclude with strengths and limitations for implementing the analytical approach in sustaining the ISS through end of life, 2020 and beyond.

Anderson, Leif↗

NASA NTRS1980

Methodology for urban rail and construction technology research and development planning

A series of transit system visits, organized by the American Public Transit Association (APTA), was conducted in which the system operators identified the most pressing development needs. These varied by property and were reformulated into a series of potential projects. To assist in the evaluation, a data base useful for estimating the present capital and operating costs of various transit system elements was generated from published data. An evaluation model was developed which considered the rate of deployment of the research and development project, potential benefits, development time and cost. An outline of an evaluation methodology that considered benefits other than capital and operating cost savings was also presented. During the course of the study, five candidate projects were selected for detailed investigation; (1) air comfort systems; (2) solid state auxiliary power conditioners; (3) door systems; (4) escalators; and (5) fare collection systems. Application of the evaluation model to these five examples showed the usefulness of modeling deployment rates and indicated a need to increase the scope of the model to quantitatively consider reliability impacts.

Rubenstein, L. D.↗

NASA NTRS1983

Burner liner thermal/structural load modelling

The objective of this program is to develop a thermal data transfer computer program module for the burner liner thermal structural load modeling program. This will be accomplished by (1) reviewing existing methodologies for thermal data transfer and selecting three heat transfer codes for application in this program; (2) evaluating the selected codes to establish criteria for developing a computer program module to transfer thermal data from the heat transfer codes to selected stress analysis codes; (3) developing the automated thermal load transfer module; and (4) verifying and documenting the module. In aircraft turbine engine hot section components, cyclic thermal stresses are the most important damage mechanism. Consequently, accurate and reliable prediction of thermal loads is essential to improving durability. To achieve this goal, a considerable effort over the past 20 years has been devoted to the acquisition of engine temperature test data, as well as the development of accurate, reliable, and efficient computer codes for the prediction of steady state and transient temperatures and for the calculation of elastic and inelastic cyclic stresses and strains in hot section components. There is a need for continued development of these codes, because the availability of more accurate analysis techniques for complex configurations has enabled engine designers to use more sophisticated designs to achieve higher cycle efficiency and reduce weight.

Maffeo, R. J.↗

NASA NTRS1985

HPOTP low-speed flexible rotor balancing, phase 1

A method was developed that shows promise in overcoming many balancing limitations. This method establishes one or more windows for low speed, out-of-housing balancing of flexible rotors. These windows are regions of speed and support flexibility where two conditions are simultaneously fulfilled. First, the rotor system behaves flexibly; therefore, there is separation among balance planes. Second, the response due to balance weights is large enough to reliably measure. The analytic formulation of the low-speed flexible rotor balancing method is described. The results of proof-of-principle tests conducted under the program are presented. Based on this effort, it is concluded that low speed flexible rotor balancing is a viable technology. In particular, the method can be used to balance a rotor bearing system at low speed which results in smooth operation above more than one bending critical speed. Furthermore, this balancing methodology is applicable to SSME turbopump rotors.

Giordano, J.↗

NASA NTRS2000

A Boundary Scan Test Vehicle for Direct Chip Attach Testing

To facilitate the new faster, better and cheaper spacecraft designs, smaller more mass efficient avionics and instruments are using higher density electronic packaging technologies such as direct chip attach (DCA). For space flight applications, these technologies need to have demonstrated reliability and reasonably well defined fabrication and assembly processes before they will be accepted as baseline designs in new missions. As electronics shrink in size, not only can repair be more difficult, but 49 probing" circuitry can be very risky and it becomes increasingly more difficult to identify the specific source of a problem. To test and monitor these new technologies, the Direct Chip Attach Task, under NASA's Electronic Parts and Packaging Program (NEPP), chose the test methodology of boundary scan testing. The boundary scan methodology was developed for interconnect integrity and functional testing at hard to access electrical nodes. With boundary scan testing, active devices are used and failures can be identified to the specific device and lead. This technology permits the incorporation of "built in test" into almost any circuit and thus gives detailed test access to the highly integrated electronic assemblies. This presentation will describe boundary scan, discuss the development of the boundary scan test vehicle for DCA and current plans for testing of direct chip attach configurations.

Parsons, Heather A.↗

NASA NTRS1975

Stochastic model for fatigue crack size and cost effective design decisions

This paper describes a methodology for making cost effective fatigue design decisions. The methodology is based on a probabilistic model for the stochastic process of fatigue crack growth with time. The development of a particular model for the stochastic process is also discussed in the paper. The model is based on the assumption of continuous time and discrete space of crack lengths. Statistical decision theory and the developed probabilistic model are used to develop the procedure for making fatigue design decisions on the basis of minimum expected cost or risk function and reliability bounds. Selections of initial flaw size distribution, NDT, repair threshold crack lengths, and inspection intervals are discussed.

Hanagud, S.↗

NASA NTRS1989

Dynamic systems-engineering process - The application of concurrent engineering

A system engineering methodology is described which enables users, particulary NASA and DOD, to accommodate changing needs; incorporate emerging technologies; identify, quantify, and manage system risks; manage evolving functional requirements; track the changing environment; and reduce system life-cycle costs. The approach is a concurrent, dynamic one which starts by constructing a performance model defining the required system functions and the interrelationships. A detailed probabilistic risk assessment of the system elements and their interrelationships is performed, and quantitative analysis of the reliability and maintainability of an engineering system allows its different technical and process failure modes to be identified and their probabilities to be computed. Decision makers can choose technical solutions that maximize an objective function and minimize the probability of failure under resource constraints.

Wiskerchen, Michael J.↗

NASA NTRS1999

Numerical Predictions of Wind Turbine Power and Aerodynamic Loads for the NREL Phase II and IV Combined Experiment Rotor

Accurate, reliable and robust numerical predictions of wind turbine rotor power remain a challenge to the wind energy industry. The literature reports various methods that compare predictions to experiments. The methods vary from Blade Element Momentum Theory (BEM), Vortex Lattice (VL), to variants of Reynolds-averaged Navier-Stokes (RaNS). The BEM and VL methods consistently show discrepancies in predicting rotor power at higher wind speeds mainly due to inadequacies with inboard stall and stall delay models. The RaNS methodologies show promise in predicting blade stall. However, inaccurate rotor vortex wake convection, boundary layer turbulence modeling and grid resolution has limited their accuracy. In addition, the inherently unsteady stalled flow conditions become computationally expensive for even the best endowed research labs. Although numerical power predictions have been compared to experiment. The availability of good wind turbine data sufficient for code validation experimental data that has been extracted from the IEA Annex XIV download site for the NREL Combined Experiment phase II and phase IV rotor. In addition, the comparisons will show data that has been further reduced into steady wind and zero yaw conditions suitable for comparisons to "steady wind" rotor power predictions. In summary, the paper will present and discuss the capabilities and limitations of the three numerical methods and make available a database of experimental data suitable to help other numerical methods practitioners validate their own work.

Duque, Earl P. N.↗

NASA NTRS1982

Applications of aerospace technology in biology and medicine

Utilization of National Aeronautics and Space Administration (NASA) technology in medicine is discussed. The objective is best obtained by stimulation of the introduction of new or improved commercially available medical products incorporating aerospace technology. A bipolar donor/recipient model of medical technology transfer is presented to provide a basis for the team's methodology. That methodology is designed to: (1) identify medical problems and NASA technology that, in combination, constitute opportunities for successful medical products; (2) obtain the early participation of industry in the transfer process; and (3) obtain acceptance by the medical community of new medical products based on NASA technology. Two commercial transfers were completed: the Stowaway, a lightweight wheelchair that provides mobility for the disabled and elderly in the cabin of commercial aircraft, and Micromed, a portable medication infusion pump for the reliable, continuous infusion of medications such as heparin or insulin. The marketing and manufacturing factors critical to the commercialization of the lightweight walker incorporating composite materials were studied. Progress was made in the development and commercialization of each of the 18 currently active projects.

Bass, B.↗

NASA NTRS1993

Design, analysis, and testing of high frequency passively damped struts

Objectives of the research are: (1) to develop design requirements for damped struts to stabilize control system in the high frequency cross-over and spill-over range; (2) to design, fabricate and test viscously damped strut and viscoelastically damped strut; (3) to verify accuracy of design and analysis methodology of damped struts; and (4) to design and build test apparatus, and develop data reduction algorithm to measure strut complex stiffness. In order to meet the stringent performance requirements of the SPICE experiment, the active control system is used to suppress the dynamic responses of the low order structural modes. However, the control system also inadvertently drives some of the higher order modes unstable in the cross-over and spill-over frequency range. Passive damping is a reliable and effective way to provide damping to stabilize the control system. It also improves the robustness of the control system. Damping is designed into the SPICE testbed as an integral part of the control-structure technology.

Yiu, Y. C.↗

NASA NTRS2019

Analyses of Kennedy Space Center Tropospheric Doppler Radar Wind Profiler Data for Space Launch System Program Certification

This paper documents the methodology and results of analyses used to certify the Kennedy Space Center (KSC) Tropospheric Doppler Radar Wind Profiler (TDRWP) as input to launch commit evaluations for the National Aeronautics and Space Administration’s (NASA) Space Launch System Program (SLSP). These analyses, and the requirements that they address, were designed by the Marshall Space Flight Center Natural Environments Branch (MSFC NE) to certify that the TDRWP provides data of sufficient accuracy and resolution for SLSP, and that the instrument provides enough reliability to support Day-of- Launch Initialization Loads Update (DOLILU) operations. On day-of-launch (DOL), space launch vehicle operators have used data from wind profilers to reverse a previous GO call in prelaunch loads and trajectory assessments due to the profiler’s capability to quickly identify changes in the wind profile within a rapidly changing wind environment. Certification of the TDRWP would allow SLSP to use DOL wind data generated by the TDRWP to design the vehicle trajectory and to verify trajectory and load constraints during the countdown for launch commit decision.

Barbre, Robert E., Jr.↗

NASA NTRSDate not supplied

Lessons Learned from Astrobee Operations on the International Space Station

Since its launch in 2019, NASA has been operating three Astrobee free-flying robots providing an autonomous and adaptable research platform aboard the International Space Station (ISS). These robots have not only facilitated a myriad of national and international research endeavors in microgravity but have also served as a STEM outreach platform for student competitions aboard the ISS. Amidst its extensive operational tenure, spanning over five years and exceeding 1200 hours of cumulative free-flyer operation as of April 2024, the Astrobee robots have encountered software and hardware anomalies. Despite its inherent design for on-orbit repair or replacement, certain anomalies have proven to be complex, necessitating remote resolution via software and firmware updates or, in extreme cases, hardware replacements or the return of faulty units to NASA's ground facilities for repair. Such challenges underscore the delicate balance between the autonomous functionality of Astrobee and the occasional need for human intervention to maintain optimal performance. One recurring point of failure identified during Astrobee's operational lifespan has been the SD card, a critical component utilized by the different Astrobee processors and the Dock Station. The occurrence of SD card anomalies, both on orbit and within ground units, has provided invaluable insights into the improvement of Astrobee's systems and mitigation to future faults. This presentation will focus on four key areas: 1. Overview of Faults and Anomalies: A comprehensive examination of the diverse array of faults and anomalies encountered by Astrobee and its associated systems both in orbit and on the ground. From software glitches to hardware malfunctions, this section provides insights into the challenges faced during Astrobee's operational tenure. 2. Resolution Processes and Procedures: An in-depth discussion of the methodologies and procedures implemented to resolve the encountered anomalies. This includes remote troubleshooting, software patches, firmware updates, and, when necessary, the logistics involved in hardware replacements or down-massing for repair. 3. Implementation of Software Updates and Hardware Upgrades: A detailed exploration of the strategies employed to mitigate the risk of recurring anomalies through the implementation of software updates and hardware upgrades. This section highlights the iterative nature of Astrobee's development, emphasizing the continuous pursuit of robustness and reliability. 4. Lessons Learned and Future Directions: Reflecting on the insights gained from addressing anomalies, this section examines the lessons learned and outlines future directions for enhancing Astrobee's robustness and resilience. It underscores the iterative nature of space exploration and the importance of adaptability and continuous improvement in the pursuit of scientific discovery. Through a nuanced examination of Astrobee's operational challenges and the strategies employed to overcome them, this presentation sheds light on the complexities of operating autonomous robotic systems in the ISS environment. It underscores NASA's commitment to pushing the boundaries of exploration and innovation while navigating the inherent challenges of space exploration.

Astrobee↗

NASA NTRSDate not supplied

Lessons Learned from Astrobee Operations on the International Space Station

Since its launch in 2019, NASA has been operating three Astrobee free-flying robots providing an autonomous and adaptable research platform aboard the International Space Station (ISS). These robots have not only facilitated a myriad of national and international research endeavors in microgravity but have also served as a STEM outreach platform for student competitions aboard the ISS. Amidst its extensive operational tenure, spanning over five years and exceeding 1200 hours of cumulative free-flyer operation as of April 2024, the Astrobee robots have encountered software and hardware anomalies. Despite its inherent design for on-orbit repair or replacement, certain anomalies have proven to be complex, necessitating remote resolution via software and firmware updates or, in extreme cases, hardware replacements or the return of faulty units to NASA's ground facilities for repair. Such challenges underscore the delicate balance between the autonomous functionality of Astrobee and the occasional need for human intervention to maintain optimal performance. One recurring point of failure identified during Astrobee's operational lifespan has been the SD card, a critical component utilized by the different Astrobee processors and the Dock Station. The occurrence of SD card anomalies, both on orbit and within ground units, has provided invaluable insights into the improvement of Astrobee's systems and mitigation to future faults. This presentation will focus on four key areas: 1. Overview of Faults and Anomalies: A comprehensive examination of the diverse array of faults and anomalies encountered by Astrobee and its associated systems both in orbit and on the ground. From software glitches to hardware malfunctions, this section provides insights into the challenges faced during Astrobee's operational tenure. 2. Resolution Processes and Procedures: An in-depth discussion of the methodologies and procedures implemented to resolve the encountered anomalies. This includes remote troubleshooting, software patches, firmware updates, and, when necessary, the logistics involved in hardware replacements or down-massing for repair. 3. Implementation of Software Updates and Hardware Upgrades: A detailed exploration of the strategies employed to mitigate the risk of recurring anomalies through the implementation of software updates and hardware upgrades. This section highlights the iterative nature of Astrobee's development, emphasizing the continuous pursuit of robustness and reliability. 4. Lessons Learned and Future Directions: Reflecting on the insights gained from addressing anomalies, this section examines the lessons learned and outlines future directions for enhancing Astrobee's robustness and resilience. It underscores the iterative nature of space exploration and the importance of adaptability and continuous improvement in the pursuit of scientific discovery. Through a nuanced examination of Astrobee's operational challenges and the strategies employed to overcome them, this presentation sheds light on the complexities of operating autonomous robotic systems in the ISS environment. It underscores NASA's commitment to pushing the boundaries of exploration and innovation while navigating the inherent challenges of space exploration.

Astrobee↗