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DOE OSTI2023

Reliability modeling in a predictive maintenance context: A margin-based approach

Current system reliability methods (typically based on fault trees or reliability block diagrams) can effectively propagate reliability data from the asset to the system level in order to identify system critical points. However, employed asset reliability data are an approximated integral representation of the past industrywide operational experience, and they neglect the present asset health status (available, for example, from online monitoring data and diagnostic assessments) and forecasted health projection (when available from prognostic models). Asset health should be informed solely by that specific asset’s current and historical performance data and should not be an approximated integral representation of the past industrywide operational experience (as currently performed by system reliability models through Bayesian updating processes). Sensor data, diagnostic assessments, and prognostic assessments are in fact not considered in plant reliability models used to inform system engineers on the most critical assets. In addition, the propagation of quantitative health data from the asset to the system level is a challenge given the diverse nature and structure of health data elements (e.g., vibration spectra, temperature readings, expected failure time). Ideally, in a predictive maintenance context, system reliability models should support decision making by propagating available health information from the asset to the system level in order to provide a quantitative snapshot of system health and identify the most critical assets. Here, this paper is directly addressing these two goals by proposing a different approach for reliability modeling that relies on asset diagnostic and prognostic assessments, along with monitoring data to measure asset health. The propagation of health data from the asset to the system level is performed through fault tree models not in probability terms, but in terms of margin where margin is the “distance” between the present status and an undesired event (e.g., failure or unacceptable performance). Through a cause-effect lens, while classical reliability models target the effect associated with asset performance, a margin-based approach focuses on the cause of an undesired asset performance (i.e., its health). Hence, thinking of reliability in terms of margins implies decision-making based on causal reasoning. We will show how fault tree models can be solved using a margin language and how this process can effectively assist system engineers to identify the most critical assets.

97 - MATHEMATICS AND COMPUTING↗

NASA NTRS2010

A High-Fidelity Simulation of a Generic Commercial Aircraft Engine and Controller

A new high-fidelity simulation of a generic 40,000 lb thrust class commercial turbofan engine with a representative controller, known as CMAPSS40k, has been developed. Based on dynamic flight test data of a highly instrumented engine and previous engine simulations developed at NASA Glenn Research Center, this non-proprietary simulation was created especially for use in the development of new engine control strategies. C-MAPSS40k is a highly detailed, component-level engine model written in MATLAB/Simulink (The MathWorks, Inc.). Because the model is built in Simulink, users have the ability to use any of the MATLAB tools for analysis and control system design. The engine components are modeled in C-code, which is then compiled to allow faster-than-real-time execution. The engine controller is based on common industry architecture and techniques to produce realistic closed-loop transient responses while ensuring that no safety or operability limits are violated. A significant feature not found in other non-proprietary models is the inclusion of transient stall margin debits. These debits provide an accurate accounting of the compressor surge margin, which is critical in the design of an engine controller. This paper discusses the development, characteristics, and capabilities of the C-MAPSS40k simulation

May, Ryan D.↗

NASA NTRS1997

NASA X-34 Technology in Motion

The X-34 technology development program is a joint industry/government project to develop, test, and operate a small, fully-reusable hypersonic flight vehicle. The objective is to demonstrate key technologies and operating concepts applicable to future reusable launch vehicles. Integrated in the vehicle are various systems to assure successful completion of mission objectives, including the Main Propulsion System (MPS). NASA-Marshall Space Flight Center (MSFC) is responsible for developing the X-34's MPS including the design and complete build package for the propulsion system components. The X-34 will be powered by the Fastrac Engine, which is currently in design and development at NASA-MSFC. Fastrac is a single-stage main engine, which burns a mixture of liquid oxygen (LOX) and kerosene(RP-1). The interface between the MPS and Fastrac engine are critical for proper system operation and technologies applicable to future reusable launch vehicles. Deneb's IGRIP software package with the Dynamic analysis option provided a key tool for conducting studies critical to this interface as well as a mechanism to drive the design of the LOX and RP-1 feedlines. Kinematic models were created for the Fastrac Engine and the feedlines for various design concepts. Based on the kinematic simulation within Envision, design and joint limits were verified and system interference controlled. It was also critical to the program to evaluate the effect of dynamic loads visually, providing a verification tool for dynamic analysis and in some cases uncovering areas that had not been considered. Deneb's software put the X-34 technology in motion and has been a key factor in facilitating the strenuous design schedule.

Beech, Geoffrey↗

NASA NTRS1992

Domain modeling and grid generation for multi-block structured grids with application to aerodynamic and hydrodynamic configurations

About five years ago, a joint development was started of a flow simulation system for engine-airframe integration studies on propeller as well as jet aircraft. The initial system was based on the Euler equations and made operational for industrial aerodynamic design work. The system consists of three major components: a domain modeller, for the graphical interactive subdivision of flow domains into an unstructured collection of blocks; a grid generator, for the graphical interactive computation of structured grids in blocks; and a flow solver, for the computation of flows on multi-block grids. The industrial partners of the collaboration and NLR have demonstrated that the domain modeller, grid generator and flow solver can be applied to simulate Euler flows around complete aircraft, including propulsion system simulation. Extension to Navier-Stokes flows is in progress. Delft Hydraulics has shown that both the domain modeller and grid generator can also be applied successfully for hydrodynamic configurations. An overview is given about the main aspects of both domain modelling and grid generation.

Spekreijse, S. P.↗

DOE OSTI2022

Evaluating Image Classification Deep Convolutional Neural Network Architectures for Remaining Useful Life Estimation of Turbofan Engines

Accurate estimation of the remaining useful life (RUL) is a key component of condition-based maintenance (CBM) and prognosis and health management (PHM). Data-based models for the estimation of RUL are of particular interest because expert knowledge of systems is not always available, and physical modeling is often not feasible. Additionally, using data-based models, which make decisions based on raw sensor data, allow features to be learned instead of manually determined. In this work, deep convolutional neural network (CNN) architectures are investigated for their ability to estimate the RUL of turbofan engines. To improve the accuracy of the models, CNN architectures, which have proven successful in image classification, are implemented and tested. Specifically, the blocks used in the Visual Geometry Group (VGG) architecture, inception modules used in the GoogLeNet architecture, and residual blocks used in the ResNet architecture are incorporated. To account for varying flight lengths, the input to the models is a window of time series data collected from the engine under test. Window locations at the climb, cruise, and descent stages are considered. To further improve the RUL estimations, multiple overlapping windows at each location are used. This increases the amount of training data available and is found to increase the accuracy of the resulting RUL estimations by averaging the estimates from all overlapping segments. The model is trained and tested using the new Commercial Modular Aero-Propulsion System Simulation (N-CMAPSS) data set, and high prognosis accuracy was achieved. Furthermore, this work expands on the model developed and used in the 2021 PHM Society Data Challenge, which received second place.

convolutional neural networks↗

NASA NTRS2001

Using Dynamic Interface Modeling and Simulation to Develop a Launch and Recovery Flight Simulation for a UH-60A Blackhawk

Joint Shipboard Helicopter Integration Process (JSHIP) is a Joint Test and Evaluation (JT&E) program sponsored by the Office of the Secretary of Defense (OSD). Under the JSHDP program is a simulation effort referred to as the Dynamic Interface Modeling and Simulation System (DIMSS). The purpose of DIMSS is to develop and test the processes and mechanisms that facilitate ship-helicopter interface testing via man-in-the-loop ground-based flight simulators. Specifically, the DIMSS charter is to develop an accredited process for using a flight simulator to determine the wind-over-the-deck (WOD) launch and recovery flight envelope for the UH-60A ship/helicopter combination. DIMSS is a collaborative effort between the NASA Ames Research Center and OSD. OSD determines the T&E and warfighter training requirements, provides the programmatics and dynamic interface T&E experience, and conducts ship/aircraft interface tests for validating the simulation. NASA provides the research and development element, simulation facility, and simulation technical experience. This paper will highlight the benefits of the NASA/JSHIP collaboration and detail achievements of the project in terms of modeling and simulation. The Vertical Motion Simulator (VMS) at NASA Ames Research Center offers the capability to simulate a wide range of simulation cueing configurations, which include visual, aural, and body-force cueing devices. The system flexibility enables switching configurations io allow back-to-back evaluation and comparison of different levels of cueing fidelity in determining minimum training requirements. The investigation required development and integration of several major simulation system at the VMS. A new UH-60A BlackHawk interchangeable cab that provides an out-the-window (OTW) field-of-view (FOV) of 220 degrees in azimuth and 70 degrees in elevation was built. Modeling efforts involved integrating Computational Fluid Dynamics (CFD) generated data of an LHA ship airwake and integrating a real-time ship motion model developed based on a batch model from Naval Surface Warfare Center. Engineering development and integration of a three degrees-of-freedom (DOF) dynamic seat to simulate high frequency rotor-dynamics dependent motion cues for use in conjunction with the large motion system was accomplished. The development of an LHA visual model in several different levels of resolution and an aural cueing system in which three separate fidelity levels could be selected were developed. VMS also integrated a PC-based E&S simFUSION system to investigate cost effective IG alternatives. The DIMSS project consists of three phases that follow an approved Validation, Verification and accreditation (VV&A) process. The first phase will support the accreditation of the individual subsystems and models. The second will follow the verification and validation of the integrated subsystems and models, and will address fidelity requirements of the integrated models and subsystems. The third and final phase will allow the verification and validation of the full system integration. This VV&A process will address the utility of the simulated WOD launch and recovery envelope. Simulations supporting the first two stages have been completed and the data is currently being reviewed and analyzed.

Sweeney, Christopher↗

NASA NTRS1989

Modeling, simulation, and analysis of optical remote sensing systems

Remote Sensing of the Earth's resources from space-based sensors has evolved in the past 20 years from a scientific experiment to a commonly used technological tool. The scientific applications and engineering aspects of remote sensing systems have been studied extensively. However, most of these studies have been aimed at understanding individual aspects of the remote sensing process while relatively few have studied their interrelations. A motivation for studying these interrelationships has arisen with the advent of highly sophisticated configurable sensors as part of the Earth Observing System (EOS) proposed by NASA for the 1990's. Two approaches to investigating remote sensing systems are developed. In one approach, detailed models of the scene, the sensor, and the processing aspects of the system are implemented in a discrete simulation. This approach is useful in creating simulated images with desired characteristics for use in sensor or processing algorithm development. A less complete, but computationally simpler method based on a parametric model of the system is also developed. In this analytical model the various informational classes are parameterized by their spectral mean vector and covariance matrix. These class statistics are modified by models for the atmosphere, the sensor, and processing algorithms and an estimate made of the resulting classification accuracy among the informational classes. Application of these models is made to the study of the proposed High Resolution Imaging Spectrometer (HRIS). The interrelationships among observational conditions, sensor effects, and processing choices are investigated with several interesting results.

Kerekes, John Paul↗

NASA NTRS2017

Automated Analysis of Stateflow Models

Stateflow is a widely used modeling framework for embedded and cyber physical systems where control software interacts with physical processes. In this work, we present a framework a fully automated safety verification technique for Stateflow models. Our approach is two-folded: (i) we faithfully compile Stateflow models into hierarchical state machines, and (ii) we use automated logic-based verification engine to decide the validity of safety properties. The starting point of our approach is a denotational semantics of State flow. We propose a compilation process using continuation-passing style (CPS) denotational semantics. Our compilation technique preserves the structural and modal behavior of the system. The overall approach is implemented as an open source toolbox that can be integrated into the existing Mathworks Simulink Stateflow modeling framework. We present preliminary experimental evaluations that illustrate the effectiveness of our approach in code generation and safety verification of industrial scale Stateflow models.

Stateflow↗

NASA NTRS2021

Simulation of Landing and Take-Off Noise for Supersonic Transport Aircraft at a Conceptual Design Fidelity Level

The German Aerospace Center has launched an internal project to assess the noise impact associated with supersonic transport aircraft during approach and departure. A dedicated simulation process is established to cover all relevant disciplines, i.e., aircraft and engine design, engine installation effects, flight simulation, and system noise prediction. The core of the simulation process is comprised of methods at the complexity and fidelity level of conceptual aircraft design, i.e., typical overall aircraft design methods and a semi-empirical approach for the noise modeling. Dedicated interfaces allow to process data from high fidelity simulation that will support or even replace initial low fidelity results in the long run. All of the results shown and discussed in this study are limited to the fidelity level of conceptual design. The application of the simulation process to the NASA 55t Supersonic Technology Concept Aeroplane, i.e., based on non-proprietary data for this vehicle, yields similar noise level predictions when compared to the published NASA results. This is used as an initial feasibility check of the new process and confirms the underlying methods and models. Such an initial verification of the process is understood as an essential step due to the lack of available noise data for supersonic transport aircraft in general. The advantageous effect of engine noise shielding on the resulting system noise is demonstrated based on predicted level time histories and certification noise levels. After this initial verification, the process is applied to evaluate a conceptual supersonic transport design based on a PhD thesis with two engines mounted under the wing, which is referred to as aircraft TWO. Full access to this vehicle’s design and performance data allows to investigate the influence of flight procedures on the resulting noise impact along approach and departure. These noise results are then assembled according to proposed Federal Aviation Agency regulations in their Notice of Proposed Rulemaking, e.g., speed limitations, for Supersonic transport noise certification and the regulations from Noise Chapters of the Annex 16 from the International Civil Aviation Organization in order to evaluate the resulting levels as a function of the flight procedure.

noise↗

NASA NTRS2005

Performance Evaluation of a Data Validation System

Online data validation is a performance-enhancing component of modern control and health management systems. It is essential that performance of the data validation system be verified prior to its use in a control and health management system. A new Data Qualification and Validation (DQV) Test-bed application was developed to provide a systematic test environment for this performance verification. The DQV Test-bed was used to evaluate a model-based data validation package known as the Data Quality Validation Studio (DQVS). DQVS was employed as the primary data validation component of a rocket engine health management (EHM) system developed under NASA's NGLT (Next Generation Launch Technology) program. In this paper, the DQVS and DQV Test-bed software applications are described, and the DQV Test-bed verification procedure for this EHM system application is presented. Test-bed results are summarized and implications for EHM system performance improvements are discussed.

Wong, Edmond↗

NASA NTRS1992

Knowledge-based approach for generating target system specifications from a domain model

Several institutions in industry and academia are pursuing research efforts in domain modeling to address unresolved issues in software reuse. To demonstrate the concepts of domain modeling and software reuse, a prototype software engineering environment is being developed at George Mason University to support the creation of domain models and the generation of target system specifications. This prototype environment, which is application domain independent, consists of an integrated set of commercial off-the-shelf software tools and custom-developed software tools. This paper describes the knowledge-based tool that was developed as part of the environment to generate target system specifications from a domain model.

Gomaa, Hassan↗

NASA NTRS1990

An AD100 implementation of a real-time STOVL aircraft propulsion system

A real-time dynamic model of the propulsion system for a Short Take-Off and Vertical Landing (STOVL) aircraft was developed for the AD100 simulation environment. The dynamic model was adapted from a FORTRAN based simulation using the dynamic programming capabilities of the AD100 ADSIM simulation language. The dynamic model includes an aerothermal representation of a turbofan jet engine, actuator and sensor models, and a multivariable control system. The AD100 model was tested for agreement with the FORTRAN model and real-time execution performance. The propulsion system model was also linked to an airframe dynamic model to provide an overall STOVL aircraft simulation for the purposes of integrated flight and propulsion control studies. An evaluation of the AD100 system for use as an aircraft simulation environment is included.

Ouzts, Peter J.↗

NASA NTRSDate not supplied

Acoustic Simulations of Two-stage Fans Behind a Supersonic Inlet

NASA created, validated, and applied a high fidelity simulation toolchain for noise prediction of a fan system for a near-term civilian supersonic aircraft engine. A high fidelity inlet and multistage fan design were acquired as the basis for physics based computational studies. The overall tone noise was computed, which was used to help improve empirical models of fan inlet noise for system analysis purposes. Additional insights were gained during the study of the fan installation details and these are shared in this paper. Both overall amplitudes and variations due to design details should be of interest to engineers tasked with designing quiet fan systems for supersonic commercial aircraft. The outlook for high-fidelity simulations of aft fan noise and installation effects will also be discussed.

fans↗

NASA NTRSDate not supplied

Acoustic Simulations of Two-stage Fans Behind a Supersonic Inlet

fan↗

DOE OSTI2019

Quantized Electronic Doping towards Atomically Controlled “Charge-Engineered” Semiconductor Nanocrystals

“Charge engineering” of semiconductor nanocrystals (NCs) through so-called electronic impurity doping is a long-standing challenge in colloidal chemistry and holds promise for ground-breaking advancements in many optoelectronic, photonic, and spin-based nanotechnologies. To date, our knowledge is limited to a few paradigmatic studies on a small number of model compounds and doping conditions, with important electronic dopants still unexplored in nanoscale systems. Equally importantly, fine-tuning of charge engineered NCs is hampered by the statistical limitations of traditional approaches. The resulting intrinsic doping inhomogeneity restricts fundamental studies to statistically averaged behaviors and complicates the realization of advanced device concepts based on their advantageous functionalities. We aim to address these issues by realizing the first example of II–VI NCs electronically doped with an exact number of heterovalent gold atoms, a known p-type acceptor impurity in bulk chalcogenides. Single-dopant accuracy across entire NC ensembles is obtained through a novel non-injection synthesis employing ligand-exchanged gold clusters as “quantized” dopant sources to seed the nucleation of CdSe NCs in organic media. Structural, spectroscopic, and magneto-optical investigations trace a comprehensive picture of the physical processes resulting from the exact doping level of the NCs. Gold atoms, doped here for the first time into II–VI NCs, are found to incorporate as nonmagnetic Au + species activating intense size-tunable intragap photoluminescence and artificially offsetting the hole occupancy of valence band states. Fundamentally, the transient conversion of Au + to paramagnetic Au 2+ (5d 9 configuration) under optical excitation results in strong photoinduced magnetism and diluted magnetic semiconductor behavior revealing the contribution of individual paramagnetic impurities to the macroscopic magnetism of the NCs. Altogether, our results demonstrate a new chemical approach toward NCs with physical functionalities tailored to the single impurity level and offer a versatile platform for future investigations and device exploitation of individual and collective impurity processes in quantum confined structures.

36 MATERIALS SCIENCE↗

NASA NTRS1999

True Concurrent Thermal Engineering Integrating CAD Model Building with Finite Element and Finite Difference Methods

Thermal engineering has long been left out of the concurrent engineering environment dominated by CAD (computer aided design) and FEM (finite element method) software. Current tools attempt to force the thermal design process into an environment primarily created to support structural analysis, which results in inappropriate thermal models. As a result, many thermal engineers either build models "by hand" or use geometric user interfaces that are separate from and have little useful connection, if any, to CAD and FEM systems. This paper describes the development of a new thermal design environment called the Thermal Desktop. This system, while fully integrated into a neutral, low cost CAD system, and which utilizes both FEM and FD methods, does not compromise the needs of the thermal engineer. Rather, the features needed for concurrent thermal analysis are specifically addressed by combining traditional parametric surface based radiation and FD based conduction modeling with CAD and FEM methods. The use of flexible and familiar temperature solvers such as SINDA/FLUINT (Systems Improved Numerical Differencing Analyzer/Fluid Integrator) is retained.

Panczak, Tim↗

NASA NTRS2012

Antenna Calibration and Measurement Equipment

A document describes the Antenna Calibration & Measurement Equipment (ACME) system that will provide the Deep Space Network (DSN) with instrumentation enabling a trained RF engineer at each complex to perform antenna calibration measurements and to generate antenna calibration data. This data includes continuous-scan auto-bore-based data acquisition with all-sky data gathering in support of 4th order pointing model generation requirements. Other data includes antenna subreflector focus, system noise temperature and tipping curves, antenna efficiency, reports system linearity, and instrument calibration. The ACME system design is based on the on-the-fly (OTF) mapping technique and architecture. ACME has contributed to the improved RF performance of the DSN by approximately a factor of two. It improved the pointing performances of the DSN antennas and productivity of its personnel and calibration engineers.

Rochblatt, David J.↗

NASA NTRS2021

Modernizing NASA’s Space Flight Safety and Mission Success (S&MS) Assurance Framework In Line With Evolving Acquisition Strategies and Systems Engineering Practices

This paper presents the objectives-driven, case-based safety and mission success (S&MS) assurance framework being developed by the NASA Office of Safety and Mission Assurance (OSMA), including its motivations and its implementation via a S&MS Assurance Standard that is under development, supplemented by supporting standards including an S&MS Analysis Management Standard that is also under development. A need to evolve NASA’s S&MS assurance framework has emerged in recent years, resulting from the need to accommodate new acquisition models; the need to accommodate evolving systems engineering (SE) practices; the need to stipulate acceptable levels of S&MS risk; the need for improved integration of S&MS into SE; and the need for clearer risk acceptance accountability. The objectives-driven, case-based S&MS assurance framework proposed here is responsive to that need. Its key features include: • The establishment, by NASA Acquirers, of fundamental S&MS performance objectives that define limits of acceptability for the likelihoods that mission technical objectives will be accomplished and that people, assets, and environments put at risk by the mission will not be adversely affected; • The development and approval of Providers’ S&MS plans for meeting Acquirers’ S&MS performance objectives, including commitments to support Acquirer audit, investigation, and reporting needs; • The development, by Providers, of S&MS assurance cases that argue, supported by evidence, that the Provider has met, or is on track to meeting, the fundamental S&MS objectives; • The evaluation, throughout the program/project life cycle, of Provider S&MS assurance cases as the primary S&MS-related technical basis for Acquirer risk acceptance and the granting to the Provider of authority to proceed through the program/project life cycle. This proposed S&MS assurance framework is notable for its lack of prescription of traditional S&MS requirements and strategies such as defined failure tolerances, margins, or analysis requirements. Instead, Providers are given latitude to propose their own strategies for meeting the fundamental S&MS performance objectives, subject to independent review and Acquirer approval. The result is a framework for S&MS assurance that is at once both rigorous and flexible.

Assurance Case↗