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On the design of fault-tolerant robotic manipulator systems

Robotic systems are finding increasing use in space applications. Many of these devices are going to be operational on board the Space Station Freedom. Fault tolerance has been deemed necessary because of the criticality of the tasks and the inaccessibility of the systems to maintenance and repair. Design for fault tolerance in manipulator systems is an area within robotics that is without precedence in the literature. In this paper, we will attempt to lay down the foundations for such a technology. Design for fault tolerance demands new and special approaches to design, often at considerable variance from established design practices. These design aspects, together with reliability evaluation and modeling tools, are presented. Mechanical architectures that employ protective redundancies at many levels and have a modular architecture are then studied in detail. Once a mechanical architecture for fault tolerance has been derived, the chronological stages of operational fault tolerance are investigated. Failure detection, isolation, and estimation methods are surveyed, and such methods for robot sensors and actuators are derived. Failure recovery methods are also presented for each of the protective layers of redundancy. Failure recovery tactics often span all of the layers of a control hierarchy. Thus, a unified framework for decision-making and control, which orchestrates both the nominal redundancy management tasks and the failure management tasks, has been derived. The well-developed field of fault-tolerant computers is studied next, and some design principles relevant to the design of fault-tolerant robot controllers are abstracted. Conclusions are drawn, and a road map for the design of fault-tolerant manipulator systems is laid out with recommendations for a 10 DOF arm with dual actuators at each joint.

Tesar, Delbert

Low-overhead transversal fault tolerance for universal quantum computation

Fast, reliable logical operations are essential for realizing useful quantum computers. By redundantly encoding logical qubits into many physical qubits and using syndrome measurements to detect and correct errors, we can achieve low logical error rates. However, for many practical quantum error correction codes such as the surface code, owing to syndrome measurement errors, standard constructions require multiple extraction rounds—of the order of the code distance d—for fault-tolerant computation, particularly considering fault-tolerant state preparation. Here we show that logical operations can be performed fault-tolerantly with only a constant number of extraction rounds for a broad class of quantum error correction codes, including the surface code with magic state inputs and feedforward, to achieve ‘transversal algorithmic fault tolerance’. Through the combination of transversal operations7 and new strategies for correlated decoding, despite only having access to partial syndrome information, we prove that the deviation from the ideal logical measurement distribution can be made exponentially small in the distance, even if the instantaneous quantum state cannot be made close to a logical codeword because of measurement errors. We supplement this proof with circuit-level simulations in a range of relevant settings, demonstrating the fault tolerance and competitive performance of our approach. Furthermore, our work sheds new light on the theory of quantum fault tolerance and has the potential to reduce the space–time cost of practical fault-tolerant quantum computation by over an order of magnitude.

Zhou, Hengyun [QuEra Computing, Boston, MA (United

Fault-tolerant software - Experiment with the sift operating system

Results are presented of an experiment conducted in the NASA Avionics Integrated Research Laboratory (AIRLAB) to investigate the implementation of fault-tolerant software techniques on fault-tolerant computer architectures, in particular the Software Implemented Fault Tolerance (SIFT) computer. The N-version programming and recovery block techniques were implemented on a portion of the SIFT operating system. The results indicate that, to effectively implement fault-tolerant software design techniques, system requirements will be impacted and suggest that retrofitting fault-tolerant software on existing designs will be inefficient and may require system modification.

Brunelle, J. E.

A fault-tolerant intelligent robotic control system

This paper describes the concept, design, and features of a fault-tolerant intelligent robotic control system being developed for space and commercial applications that require high dependability. The comprehensive strategy integrates system level hardware/software fault tolerance with task level handling of uncertainties and unexpected events for robotic control. The underlying architecture for system level fault tolerance is the distributed recovery block which protects against application software, system software, hardware, and network failures. Task level fault tolerance provisions are implemented in a knowledge-based system which utilizes advanced automation techniques such as rule-based and model-based reasoning to monitor, diagnose, and recover from unexpected events. The two level design provides tolerance of two or more faults occurring serially at any level of command, control, sensing, or actuation. The potential benefits of such a fault tolerant robotic control system include: (1) a minimized potential for damage to humans, the work site, and the robot itself; (2) continuous operation with a minimum of uncommanded motion in the presence of failures; and (3) more reliable autonomous operation providing increased efficiency in the execution of robotic tasks and decreased demand on human operators for controlling and monitoring the robotic servicing routines.

Marzwell, Neville I.

SIFT - Design and analysis of a fault-tolerant computer for aircraft control

SIFT (Software Implemented Fault Tolerance) is an ultrareliable computer for critical aircraft control applications that achieves fault tolerance by the replication of tasks among processing units. The main processing units are off-the-shelf minicomputers, with standard microcomputers serving as the interface to the I/O system. Fault isolation is achieved by using a specially designed redundant bus system to interconnect the processing units. Error detection and analysis and system reconfiguration are performed by software. Iterative tasks are redundantly executed, and the results of each iteration are voted upon before being used. Thus, any single failure in a processing unit or bus can be tolerated with triplication of tasks, and subsequent failures can be tolerated after reconfiguration. Independent execution by separate processors means that the processors need only be loosely synchronized, and a novel fault-tolerant synchronization method is described.

Wensley, J. H.

Hardware and software fault tolerance - A unified architectural approach

The loss of hardware fault tolerance which often arises when design diversity is used to improve the fault tolerance of computer software is considered analytically, and a unified design approach is proposed to avoid the problem. The fundamental theory of fault-tolerant (FT) architectures is reviewed; the current status of design-diversity software development is surveyed; and the FT-processor/attached-processor (FTP/AP) architecture developed by Lala et al. (1986) is described in detail and illustrated with diagrams. FTP/AP is shown to permit efficient implementation of N-version FT software while still tolerating random hardware failures with very high coverage; the reliability is found to be significantly higher than that of conventional majority-vote N-version software.

Lala, Jaynarayan H.

A survey and comparison of fault-tolerant multistage interconnection networks

Intrinsically fault-tolerant multistage interconnection networks (MINs) are surveyed, categorizing the MINs by the amount of hardware modifications they use to provide redundancy. The diversity of such MINs and the scope of fault-tolerance techniques are examined. A hypothetical MIN with ideal engineering characteristics is defined, and the surveyed MINs are compared to this standard.

Adams, George B., III

Fault-tolerant multichannel demultiplexer subsystems

Fault tolerance in future processing and switching communication satellites is addressed by showing new methods for detecting hardware failures in the first major subsystem, the multichannel demultiplexer. An efficient method for demultiplexing frequency slotted channels uses multirate filter banks which contain fast Fourier transform processing. All numerical processing is performed at a lower rate commensurate with the small bandwidth of each bandbase channel. The integrity of the demultiplexing operations is protected by using real number convolutional codes to compute comparable parity values which detect errors at the data sample level. High rate, systematic convolutional codes produce parity values at a much reduced rate, and protection is achieved by generating parity values in two ways and comparing them. Parity values corresponding to each output channel are generated in parallel by a subsystem, operating even slower and in parallel with the demultiplexer that is virtually identical to the original structure. These parity calculations may be time shared with the same processing resources because they are so similar.

Redinbo, Robert

Reliability modeling of fault-tolerant computer based systems

Digital fault-tolerant computer-based systems have become commonplace in military and commercial avionics. These systems hold the promise of increased availability, reliability, and maintainability over conventional analog-based systems through the application of replicated digital computers arranged in fault-tolerant configurations. Three tightly coupled factors of paramount importance, ultimately determining the viability of these systems, are reliability, safety, and profitability. Reliability, the major driver affects virtually every aspect of design, packaging, and field operations, and eventually produces profit for commercial applications or increased national security. However, the utilization of digital computer systems makes the task of producing credible reliability assessment a formidable one for the reliability engineer. The root of the problem lies in the digital computer's unique adaptability to changing requirements, computational power, and ability to test itself efficiently. Addressed here are the nuances of modeling the reliability of systems with large state sizes, in the Markov sense, which result from systems based on replicated redundant hardware and to discuss the modeling of factors which can reduce reliability without concomitant depletion of hardware. Advanced fault-handling models are described and methods of acquiring and measuring parameters for these models are delineated.

Bavuso, Salvatore J.

Fault-Tolerant Coding for State Machines

Two reliable fault-tolerant coding schemes have been proposed for state machines that are used in field-programmable gate arrays and application-specific integrated circuits to implement sequential logic functions. The schemes apply to strings of bits in state registers, which are typically implemented in practice as assemblies of flip-flop circuits. If a single-event upset (SEU, a radiation-induced change in the bit in one flip-flop) occurs in a state register, the state machine that contains the register could go into an erroneous state or could hang, by which is meant that the machine could remain in undefined states indefinitely. The proposed fault-tolerant coding schemes are intended to prevent the state machine from going into an erroneous or hang state when an SEU occurs. To ensure reliability of the state machine, the coding scheme for bits in the state register must satisfy the following criteria: 1. All possible states are defined. 2. An SEU brings the state machine to a known state. 3. There is no possibility of a hang state. 4. No false state is entered. 5. An SEU exerts no effect on the state machine. Fault-tolerant coding schemes that have been commonly used include binary encoding and "one-hot" encoding. Binary encoding is the simplest state machine encoding and satisfies criteria 1 through 3 if all possible states are defined. Binary encoding is a binary count of the state machine number in sequence; the table represents an eight-state example. In one-hot encoding, N bits are used to represent N states: All except one of the bits in a string are 0, and the position of the 1 in the string represents the state. With proper circuit design, one-hot encoding can satisfy criteria 1 through 4. Unfortunately, the requirement to use N bits to represent N states makes one-hot coding inefficient.

Naegle, Stephanie Taft

Design study of Software-Implemented Fault-Tolerance (SIFT) computer

Software-implemented fault tolerant (SIFT) computer design for commercial aviation is reported. A SIFT design concept is addressed. Alternate strategies for physical implementation are considered. Hardware and software design correctness is addressed. System modeling and effectiveness evaluation are considered from a fault-tolerant point of view.

Wensley, J. H.

The Design of a Fault-Tolerant COTS-Based Bus Architecture

In this paper, we report our experiences and findings on the design of a fault-tolerant bus architecture comprised of two COTS buses, the IEEE 1394 and the 12C. This fault-tolerant bus is the backbone system bus for the avionics architecture of the X2000 program at the Jet Propulsion Laboratory. COTS buses are attractive because of the availability of low cost commercial products. However, they are not specifically designed for highly reliable applications such as long-life deep-space missions. The X2000 design team has devised a multi-level fault tolerance approach to compensate for this shortcoming of COTS buses. First, the approach enhances the fault tolerance capabilities of the IEEE 1394 and 12 C buses by adding a layer of fault handling hardware and software. Second, algorithms are developed to enable the IEEE 1394 and the 12 C buses assist each other to isolate and recovery from faults. Third, the set of IEEE 1394 and 12 C buses is duplicated to further enhance system reliability. The X2000 design team has paid special attention to guarantee that all fault tolerance provisions will not cause the bus design to deviate from the commercial standard specifications. Otherwise, the economic attractiveness of using COTS will be diminished. The hardware and software design of the X2000 fault-tolerant bus are being implemented and flight hardware will be delivered to the ST4 and Europa Orbiter missions.

Chau, Savio N.

Fault-Tolerant Heat Exchanger

A compact, lightweight heat exchanger has been designed to be fault-tolerant in the sense that a single-point leak would not cause mixing of heat-transfer fluids. This particular heat exchanger is intended to be part of the temperature-regulation system for habitable modules of the International Space Station and to function with water and ammonia as the heat-transfer fluids. The basic fault-tolerant design is adaptable to other heat-transfer fluids and heat exchangers for applications in which mixing of heat-transfer fluids would pose toxic, explosive, or other hazards: Examples could include fuel/air heat exchangers for thermal management on aircraft, process heat exchangers in the cryogenic industry, and heat exchangers used in chemical processing. The reason this heat exchanger can tolerate a single-point leak is that the heat-transfer fluids are everywhere separated by a vented volume and at least two seals. The combination of fault tolerance, compactness, and light weight is implemented in a unique heat-exchanger core configuration: Each fluid passage is entirely surrounded by a vented region bridged by solid structures through which heat is conducted between the fluids. Precise, proprietary fabrication techniques make it possible to manufacture the vented regions and heat-conducting structures with very small dimensions to obtain a very large coefficient of heat transfer between the two fluids. A large heat-transfer coefficient favors compact design by making it possible to use a relatively small core for a given heat-transfer rate. Calculations and experiments have shown that in most respects, the fault-tolerant heat exchanger can be expected to equal or exceed the performance of the non-fault-tolerant heat exchanger that it is intended to supplant (see table). The only significant disadvantages are a slight weight penalty and a small decrease in the mass-specific heat transfer.

Izenson, Michael G.

An optimized implementation of a fault-tolerant clock synchronization circuit

A fault-tolerant clock synchronization circuit was designed and tested. A comparison to a previous design and the procedure followed to achieve the current optimization are included. The report also includes a description of the system and the results of tests performed to study the synchronization and fault-tolerant characteristics of the implementation.

Torres-Pomales, Wilfredo

High Speed Operation and Testing of a Fault Tolerant Magnetic Bearing

Research activities undertaken to upgrade the fault-tolerant facility, continue testing high-speed fault-tolerant operation, and assist in the commission of the high temperature (1000 degrees F) thrust magnetic bearing as described. The fault-tolerant magnetic bearing test facility was upgraded to operate to 40,000 RPM. The necessary upgrades included new state-of-the art position sensors with high frequency modulation and new power edge filtering of amplifier outputs. A comparison study of the new sensors and the previous system was done as well as a noise assessment of the sensor-to-controller signals. Also a comparison study of power edge filtering for amplifier-to-actuator signals was done; this information is valuable for all position sensing and motor actuation applications. After these facility upgrades were completed, the rig is believed to have capabilities for 40,000 RPM operation, though this has yet to be demonstrated. Other upgrades included verification and upgrading of safety shielding, and upgrading control algorithms. The rig will now also be used to demonstrate motoring capabilities and control algorithms are in the process of being created. Recently an extreme temperature thrust magnetic bearing was designed from the ground up. The thrust bearing was designed to fit within the existing high temperature facility. The retrofit began near the end of the summer, 04, and continues currently. Contract staff authored a NASA-TM entitled "An Overview of Magnetic Bearing Technology for Gas Turbine Engines", containing a compilation of bearing data as it pertains to operation in the regime of the gas turbine engine and a presentation of how magnetic bearings can become a viable candidate for use in future engine technology.

DeWitt, Kenneth

Fault-tolerance experiments with the JPL STAR computer.

Results of fault-tolerance experiments performed using an experimental computer with dynamic (standby) redundancy, including replaceable subsystems and a 'program rollback' provision to eliminate transient-caused errors. After a brief review of the specification of fault-tolerance with respect to transient faults, including a description of the method of injection of transient faults in software and system tests, fault-tolerance experiments carried out with this computer with regard to the determination of fault classes, software verification, system verification, and recovery stability are summarized. A test and repair processor is described which constitutes a special monitor unit of the computer and is used to obtain information for fault detection in the other subsystems of the computer and to ensure that proper recovery occurs when a fault is detected.

Avizienis, A.

Design and validation of fault-tolerant flight systems

Flight systems must be validated to show that they are consistent with the requirements of their intended applications. While high reliability is difficult to validate, the additional complexity of fault tolerance further compounds the validation problem. The objective of NASA’s research is to develop a methodology for designing validatable fault-tolerant systems. Under the design-for-validation philosophy, emphasis is placed on developing validation methods that can be incorporated into the design process right from the start and design methods and guidance which, while incorporating fault tolerance, can assure validatability. This paper examines the statistical issues of validating highly reliable, fault tolerant system. There are many problems associated with traditional methods of designing and validating these potentially complex hardware and software systems. Useful design-for-validation methods, which include structured specification and design methodologies, mathematical proof techniques, analytical modeling, simulation and emulation, and physical testing, are discussed. Important design issues associated with fault tolerance are presented along with the related validation concerns which must be addressed. Experience has shown that synchronization and Byzantine resilience must accompany fault tolerance. Other design attributes associated with fault tolerance may be used by a designer on the basis of cost, weight, performance, and validation considerations.

Computer systems

Shared memory for a fault-tolerant computer

A system is described for sharing a memory in a fault-tolerant computer. The memory is under the direct control and monitoring of error detecting and error diagnostic units in the fault-tolerant computer. This computer verifies that data to and from the memory is legally encoded and verifies that words read from the memory at a desired address are, in fact, actually delivered from that desired address. The means are provided for a second processor, which is independent of the direct control and monitoring of the error checking and diagnostic units of the fault-tolerant computer, and to share the memory of the fault-tolerant computer. Circuitry is included to verify that: (1) the processor has properly accessed a desired memory location in the memory; (2) a data word read-out from the memory is properly coded; and (3) no inactive memory was erroneously outputting data onto the shared memory bus.

Gilley, G. C.