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NASA NTRS1982

Flight evaluation of a digital electronic engine control system in an F-15 airplane

Benefits provided by a full-authority digital engine control are related to improvements in engine efficiency, performance, and operations. An additional benefit is the capability of detecting and accommodating failures in real time and providing engine-health diagnostics. The digital electronic engine control (DEEC), is a full-authority digital engine control developed for the F100-PW-100 turbofan engine. The DEEC has been flight tested on an F-15 aircraft. The flight tests had the objective to evaluate the DEEC hardware and software over the F-15 flight envelope. A description is presented of the results of the flight tests, which consisted of nonaugmented and augmented throttle transients, airstarts, and backup control operations. The aircraft, engine, DEEC system, and data acquisition and reduction system are discussed.

Myers, L. P.↗

NASA NTRS1994

Embedded parallel processing based ground control systems for small satellite telemetry

The use of networked terminals which utilize embedded processing techniques results in totally integrated, flexible, high speed, reliable, and scalable systems suitable for telemetry and data processing applications such as mission operations centers (MOC). Synergies of these terminals, coupled with the capability of terminal to receive incoming data, allow the viewing of any defined display by any terminal from the start of data acquisition. There is no single point of failure (other than with network input) such as exists with configurations where all input data goes through a single front end processor and then to a serial string of workstations. Missions dedicated to NASA's ozone measurements program utilize the methodologies which are discussed, and result in a multimission configuration of low cost, scalable hardware and software which can be run by one flight operations team with low risk.

Forman, Michael L.↗

NASA NTRS2006

NASA Crew and Cargo Launch Vehicle Development Approach Builds on Lessons from Past and Present Missions

The United States (US) Vision for Space Exploration, announced in January 2004, outlines the National Aeronautics and Space Administration's (NASA) strategic goals and objectives, including retiring the Space Shuttle and replacing it with new space transportation systems for missions to the Moon, Mars, and beyond. The Crew Exploration Vehicle (CEV) that the new human-rated Crew Launch Vehicle (CLV) lofts into space early next decade will initially ferry astronauts to the International Space Station (ISS) Toward the end of the next decade, a heavy-lift Cargo Launch Vehicle (CaLV) will deliver the Earth Departure Stage (EDS) carrying the Lunar Surface Access Module (LSAM) to low-Earth orbit (LEO), where it will rendezvous with the CEV launched on the CLV and return astronauts to the Moon for the first time in over 30 years. This paper outlines how NASA is building these new space transportation systems on a foundation of legacy technical and management knowledge, using extensive experience gained from past and ongoing launch vehicle programs to maximize its design and development approach, with the objective of reducing total life cycle costs through operational efficiencies such as hardware commonality. For example, the CLV in-line configuration is composed of a 5-segment Reusable Solid Rocket Booster (RSRB), which is an upgrade of the current Space Shuttle 4- segment RSRB, and a new upper stage powered by the liquid oxygen/liquid hydrogen (LOX/LH2) J-2X engine, which is an evolution of the J-2 engine that powered the Apollo Program s Saturn V second and third stages in the 1960s and 1970s. The CaLV configuration consists of a propulsion system composed of two 5-segment RSRBs and a 33- foot core stage that will provide the LOX/LED needed for five commercially available RS-68 main engines. The J-2X also will power the EDS. The Exploration Launch Projects, managed by the Exploration Launch Office located at NASA's Marshall Space Flight Center, is leading the design, development, testing, and operations planning for these new space transportation systems. Utilizing a foundation of heritage hardware and management lessons learned mitigates both technical and programmatic risk. Project engineers and managers work closely with the Space Shuttle Program to transition hardware, infrastructure, and workforce assets to the new launch systems, leveraging a wealth of knowledge from Shuffle operations. In addition, NASA and its industry partners have tapped into valuable Apollo databases and are applying corporate wisdom conveyed firsthand by Apollo-era veterans of America s original Moon missions. Learning from its successes and failures, NASA employs rigorous systems engineering and systems management processes and principles in a disciplined, integrated fashion to further improve the probability of mission success.

Dumbacher, Daniel L.↗

NASA NTRS2010

Application of Diagnostic Analysis Tools to the Ares I Thrust Vector Control System

The NASA Ares I Crew Launch Vehicle is being designed to support missions to the International Space Station (ISS), to the Moon, and beyond. The Ares I is undergoing design and development utilizing commercial-off-the-shelf tools and hardware when applicable, along with cutting edge launch technologies and state-of-the-art design and development. In support of the vehicle s design and development, the Ares Functional Fault Analysis group was tasked to develop an Ares Vehicle Diagnostic Model (AVDM) and to demonstrate the capability of that model to support failure-related analyses and design integration. One important component of the AVDM is the Upper Stage (US) Thrust Vector Control (TVC) diagnostic model-a representation of the failure space of the US TVC subsystem. This paper first presents an overview of the AVDM, its development approach, and the software used to implement the model and conduct diagnostic analysis. It then uses the US TVC diagnostic model to illustrate details of the development, implementation, analysis, and verification processes. Finally, the paper describes how the AVDM model can impact both design and ground operations, and how some of these impacts are being realized during discussions of US TVC diagnostic analyses with US TVC designers.

Maul, William A.↗

NASA NTRS1991

Transportation technology: Earth-to-orbit propulsion

The topics presented are covered in viewgraph form and include the following: (1) sensor autodiagnosis and autocalibration; (2) autodiagnostic and autocalibration program; (3) plume diagnostics; (4) plume diagnostics program; (5) failure modeling; (6) mass data storage and retrieval; (7) fiber optic instrumentation bus; (8) model based diagnostics; (9) safety monitoring system (SMS); (10) control and real time diagnostics; (11) current intelligent controls program; (12) augumented intelligent controls program; (13) current real time diagnostics program; (14) augumented RT diagnostics program; and (15) control and diagnostic system hardware.

Gorland, S.↗

NASA NTRS2002

Rocket Engine Oscillation Diagnostics

Rocket engine oscillating data can reveal many physical phenomena ranging from unsteady flow and acoustics to rotordynamics and structural dynamics. Because of this, engine diagnostics based on oscillation data should employ both signal analysis and physical modeling. This paper describes an approach to rocket engine oscillation diagnostics, types of problems encountered, and example problems solved. Determination of design guidelines and environments (or loads) from oscillating phenomena is required during initial stages of rocket engine design, while the additional tasks of health monitoring, incipient failure detection, and anomaly diagnostics occur during engine development and operation. Oscillations in rocket engines are typically related to flow driven acoustics, flow excited structures, or rotational forces. Additional sources of oscillatory energy are combustion and cavitation. Included in the example problems is a sampling of signal analysis tools employed in diagnostics. The rocket engine hardware includes combustion devices, valves, turbopumps, and ducts. Simple models of an oscillating fluid system or structure can be constructed to estimate pertinent dynamic parameters governing the unsteady behavior of engine systems or components. In the example problems it is shown that simple physical modeling when combined with signal analysis can be successfully employed to diagnose complex rocket engine oscillatory phenomena.

Nesman, Tom↗

NASA NTRS2009

Integrated Vehicle Ground Vibration Testing in Support of Launch Vehicle Loads and Controls Analysis

NASA has conducted dynamic tests on each major launch vehicle during the past 45 years. Each test provided invaluable data to correlate and correct analytical models. GVTs result in hardware changes to Saturn and Space Shuttle, ensuring crew and vehicle safety. Ares I IVGT will provide test data such as natural frequencies, mode shapes, and damping to support successful Ares I flights. Testing will support controls analysis by providing data to reduce model uncertainty. Value of testing proven by past launch vehicle successes and failures. Performing dynamic testing on Ares vehicles will provide confidence that the launch vehicles will be safe and successful in their missions.

Tuma, Margaret L.↗

NASA NTRS2011

An Alternative Approach to Human Servicing of Manned Earth Orbiting Spacecraft

As manned spacecraft have grown larger and more complex, they have come to rely on spacewalks or Extravehicular Activities (EVA) for both mission success and crew safety. Typically these spacecraft maintain all of the hardware and trained personnel needed to perform an EVA on-board at all times. Maintaining this capability requires volume and up-mass for storage of EVA hardware, crew time for ground and on-orbit training, and on-orbit maintenance of EVA hardware . This paper proposes an alternative methodology to utilize launch-on-need hardware and crew to provide EVA capability for space stations in Earth orbit after assembly complete, in the same way that most people would call a repairman to fix something at their home. This approach would not only reduce ground training requirements and save Intravehicular Activity (IVA) crew time in the form of EVA hardware maintenance and on-orbit training, but would also lead to more efficient EVAs because they would be performed by specialists with detailed knowledge and training stemming from their direct involvement in the development of the EVA. The on-orbit crew would then be available to focus on the immediate response to the failure as well as the day-to-day operations of the spacecraft and payloads. This paper will look at how current ISS unplanned EVAs are conducted, including the time required for preparation, and offer alternatives for future spacecraft utilizing lessons learned from ISS. As this methodology relies entirely on the on-time and on-need launch of spacecraft, any space station that utilized this approach would need a robust transportation system including more than one launch vehicle capable of carrying crew. In addition the fault tolerance of the space station would be an important consideration in how much time was available for EVA preparation after the failure. Each future program would have to weigh the risk of on-time launch against the increase in available crew time for the main objective of the spacecraft.

Mularski, John↗

NASA NTRS2010

Physics-Based Methods of Failure Analysis and Diagnostics in Human Space Flight

The Integrated Health Management (IHM) for the future aerospace systems requires to interface models of multiple subsystems in an efficient and accurate information environment at the earlier stages of system design. The complexity of modern aeronautic and aircraft systems (including e.g. the power distribution, flight control, solid and liquid motors) dictates employment of hybrid models and high-level reasoners for analysing mixed continuous and discrete information flow involving multiple modes of operation in uncertain environments, unknown state variables, heterogeneous software and hardware components. To provide the information link between key design/performance parameters and high-level reasoners we rely on development of multi-physics performance models, distributed sensors networks, and fault diagnostic and prognostic (FD&P) technologies in close collaboration with system designers. The main challenges of our research are related to the in-flight assessment of the structural stability, engine performance, and trajectory control. The main goal is to develop an intelligent IHM that not only enhances components and system reliability, but also provides a post-flight feedback helping to optimize design of the next generation of aerospace systems. Our efforts are concentrated on several directions of the research. One of the key components of our strategy is an innovative approach to the diagnostics/prognostics based on the real time dynamical inference (DI) technologies extended to encompass hybrid systems with hidden state trajectories. The major investments are into the multiphysics performance modelling that provides an access of the FD&P technologies to the main performance parameters of e.g. solid and liquid rocket motors and composite materials of the nozzle and case. Some of the recent results of our research are discussed in this chapter. We begin by introducing the problem of dynamical inference of stochastic nonlinear models and reviewing earlier results. Next, we present our analytical approach to the solution of this problem based on the path integral formulation. The resulting algorithm does not require an extensive global search for the model parameters, provides optimal compensation for the effects of dynamical noise, and is robust for a broad range of dynamical models. In the following Section the strengths of the algorithm are illustrated illustrated by inferring the parameters of the stochastic Lorenz system and comparing the results with those of earlier research. Next, we discuss a number of recent results in application to the development of the IHM for aerospace system. Firstly, we apply dynamical inference approach to a solution of classical three tank problems with mixed unknown continuous and binary parameters. The problem is considered in the context of ground support system for filling fuel tanks of liquid rocket motors. It is shown that the DI algorithm is well suited for successful solution of a hybrid version of this benchmark problem even in the presence of additional periodic and stochastic perturbation of unknown strength. Secondly, we illustrate our approach by its application to an analysis of the nozzle fault in a solid rocket motor (SRM). The internal ballistics of the SRM is modelled as a set of one-dimensional partial differential equations coupled to the dynamics of the propellant regression. In this example we are specifically focussed on the inference of discrete and continuous parameters of the nozzle blocking fault and on the possibility of an application of the DI algorithm to reducing the probability of "misses" of an on-board FD&P for SRM. In the next section re-contact problem caused by first stage/upper stage separation failure is discussed. The reaction forces imposed on the nozzle of the upper stage during the re-contact and their connection to the nozzle damage and to the thrust vector control (TVC) signal are obtained. It is shown that transient impact induced torquean be modelled as a response of an effective damped oscillator. A possible application of the DI algorithm to the inference of damage parameters and predicting fault dynamics ahead of time using the actuator signal is discussed. Finally, we formulate Bayesian inferential framework for development of the IHM system for in-flight structural health monitoring (SHM) of composite materials. We consider the signal generated by piezoelectric actuator mounted on composite structure generating elastic waves in it. The signal received by the sensor is than compared with the baseline signal. The possibility of damage inference is discussed in the context of development of the SHM.

Smelyanskiy, Vadim N.↗

NASA NTRS2005

SAFER Inspection of Space Shuttle Thermal Protection System

In the aftermath of the space shuttle Columbia accident, it quickly became clear that new methods would need to be developed that would provide the capability to inspect and repair the shuttle's thermal protection system (TPS). A boom extension to the Remote Manipulator System (RMS) with a laser topography sensor package was identified as the primary means for measuring the damage depth in acreage tile as well as scanning Reinforced Carbon- Carbon (RCC) surfaces. However, concern over the system's fault tolerance made it prudent to investigate alternate means of acquiring close range photographs and contour depth measurements in the event of a failure. One method that was identified early was to use the Simplified Aid For EVA Rescue (SAFER) propulsion system to allow EVA access to damaged areas of concern. Several issues were identified as potential hazards to SAFER use for this operation. First, the ability of an astronaut to maintain controlled flight depends upon efficient technique and hardware reliability. If either of these is insufficient during flight operations, a safety tether must be used to rescue the crewmember. This operation can jeopardize the integrity of the Extra-vehicular Mobility Unit (EMU) or delicate TPS materials. Controls were developed to prevent the likelihood of requiring a tether rescue, and procedures were written to maximize the chances for success if it cannot be avoided. Crewmember ability to manage tether cable tension during nominal flight also had to be evaluated to ensure it would not negatively affect propellant consumption. Second, although propellant consumption, flight control, orbital dynamics, and flight complexity can all be accurately evaluated in Virtual Reality (VR) Laboratory at Johnson Space Center, there are some shortcomings. As a crewmember's hand is extended to simulate measurement of tile damage, it will pass through the vehicle without resistance. In reality, this force will push the crewmember away from the vehicle, and could induce a moment which, if strong enough, could saturate the attitude control system in SAFER. This raises the concern that additional propellant will be consumed to maintain controlled flight. To account for this, the fidelity of the Virtual Reality simulation was improved to include the effect of crewmember contact with the vehicle during SAFER flight. In addition, while participating in VR simulations, the subject is in shirt sleeves and sits in a chair. This does not provide a flight-like representation of body position awareness. To prevent inadvertent contact with tile or RCC, other facilities were utilized to establish crew preferences for body attitude and tool configuration. Finally, a study was performed to determine if attitude constraints are needed for the Space shuttle and International Space Station to reduce SAFER flight difficulty.

Scoville, Zebulon C.↗

NASA NTRS2016

The Soil Moisture Acttive Passive Mission: Fault Protection Performance and Lessons Learned

Fault protection as a discipline involves a collection of flight software logic and operational processes for detecting unacceptable anomalous behavior, responding prior to reaching criticality, restricting the propagation of a failure beyond a fault containment region, and recovering the vehicle back to full or degraded functionality if possible. The System Fault Protection (SFP) design for the SMAP Earth orbiter was put to the test during its 90-day vehicle commissioning activities. During this time, the SFP software autonomously protected the vehicle from multiple faults to critical hardware, and the operations team successfully returned the observatory to its science state. The SFP also performed well in the presence of anomalous behavior below true safety limits by not taking unnecessary response actions, instead allowing the operations team time to monitor the behavior. Certain aspects of the SFP design were modified during operations via both parameter updates and a full flight software update in order to better match the vehicle behavior in the flight environment. An evaluation of the SMAP SFP performance during vehicle Commissioning will be provided in this paper, as well as a set of lessons learned largely focused on visibility, SFP mutability in operations, responses to peripheral device faults, and Safe Mode recovery and design. By capturing some of the knowledge gained during SMAP Commissioning, it is intended that this paper provide guidance for making future System Fault Protection designs more robust and supportive of operations.

Clark, Jessica↗

NASA NTRS2009

Objectives and Progress on Ground Vibration Testing for the Ares Launch Vehicles

NASA has conducted dynamic tests on each of its major launch vehicles during the past 45 years. Each test has provided invaluable data to correlate and correct analytical models used to predict structural responses to differing dynamics for these vehicles. With both Saturn V and Space Shuttle, hardware changes were also required to the flight vehicles to ensure crew and vehicle safety. The Ares I IVGVT will undoubtedly provide similar valuable test data to support successful flights of the Constellation Program. The IVGVT will provide test determined natural frequencies, mode shapes and damping for the Ares I. This data will be used to support controls analysis by providing this test data to reduce uncertainty in the models. The value of this testing has been proven by past launch vehicle successes and failures. Performing dynamic testing on the Ares vehicles will provide confidence that the launch vehicles will be safe and successful in their missions. In addition, IVGVT will provide the following benefits for the Ares rockets: a) IVGVT data along with Ares development flights like Ares I-X, Ares I-Y, Ares I-X Prime, and Orion-1 or others will reduce the risk to the Orion-2 crew. IVGVT will permit anchoring the various analytical and operational models used in so many different aspects of Ares operations. b) IVGVT data will permit better understanding of the structural and GN&C margins of the spacecraft and may permit mass savings or expanded day-of-launch opportunities or fewer constraints to launch. c) Undoubtedly IVGVT will uncover some of the "unknown unknowns" so often seen in developing, launching, and flying new spacecraft vehicles and data from IVGVT may help prevent a loss of vehicle or crew. d) IVGVT also will be the first time Ares I flight-like hardware is transported, handled, rotated, mated, stacked, and integrated. e) Furthermore, handling and stacking the IVGVT launch vehicle stacks will be an opportunity to understand certain aspects of vehicle operability much better (for example, handling procedures, touch-labor time to accomplish tasks, access at interfaces, access to stage mating bolts, access to avionics boxes, access to the Interstage, GSE functionality, and many other important aspects of Ares I operability). All of these results will provide for better vehicle safety and better stewardship of national resources as NASA begins its next phase of human space exploration.

Tuma, Margaret L.↗

NASA NTRS1972

Failure analysis of solid rocket apogee motors

The analysis followed five selected motors through initial design, development, test, qualification, manufacture, and final flight reports. An audit was conducted at the manufacturing plants to complement the literature search with firsthand observations of the current philosophies and practices that affect reliability of the motors. A second literature search emphasized acquisition of spacecraft and satellite data bearing on solid motor reliability. It was concluded that present practices at the plants yield highly reliable flight hardware. Reliability can be further improved by new developments of aft-end bonding and initiator/igniter nondestructive test methods, a safe/arm device, and an insulation formulation. Minimum diagnostic instrumentation is recommended for all motor flights. Surplus motors should be used in margin testing. Criteria should be established for pressure and zone curing. The motor contractor should be represented at launch. New design analyses should be made of stretched motors and spacecraft/motor pairs.

Martin, P. J.↗

NASA NTRS1976

Man-rated flight software for the F-8 DFBW program

The design, implementation, and verification of the flight control software used in the F-8 DFBW program are discussed. Since the DFBW utilizes an Apollo computer and hardware, the procedures, controls, and basic management techniques employed are based on those developed for the Apollo software system. Program assembly control, simulator configuration control, erasable-memory load generation, change procedures and anomaly reporting are discussed. The primary verification tools are described, as well as the program test plans and their implementation on the various simulators. Failure effects analysis and the creation of special failure generating software for testing purposes are described.

Bairnsfather, R. R.↗

NASA NTRS1986

Real-time simulator for helicopter rotor wind-tunnel operations

This paper describes the elements and operation of a simulator that is being used to train operators of the Rotor Test Apparatus (RTA) in the large-scale 40- by 80-Foot Wind Tunnel at Ames Research Center. The simulator, named TUTOR (for Tunnel Utilization Trainer with Operating Rotor) duplicates the controls of the rotor and its dynamic behavior, as well as the wind-tunnel controls. The simulation software uses a preexisting blade-element model of a four-bladed rotor with flapping and lead-lag degrees of freedom. Equations were developed for all hardware and controls of the RTA and of the wind tunnel that are normally required to perform a wind-tunnel test of a helicopter rotor. The simulator hardware consists of consoles designed to have the same appearance and functions as those in the control room of the 40- by 80-Foot Wind Tunnel, allowing input from three operators who normally establish the required operating conditions during a test run. Normal operating procedures can be practiced, as well as simulated emergencies such as rotor power failure.

Talbot, P. D.↗

NASA NTRS2010

The Importance of HRA in Human Space Flight: Understanding the Risks

Human performance is critical to crew safety during space missions. Humans interact with hardware and software during ground processing, normal flight, and in response to events. Human interactions with hardware and software can cause Loss of Crew and/or Vehicle (LOCV) through improper actions, or may prevent LOCV through recovery and control actions. Humans have the ability to deal with complex situations and system interactions beyond the capability of machines. Human Reliability Analysis (HRA) is a method used to qualitatively and quantitatively assess the occurrence of human failures that affect availability and reliability of complex systems. Modeling human actions with their corresponding failure probabilities in a Probabilistic Risk Assessment (PRA) provides a more complete picture of system risks and risk contributions. A high-quality HRA can provide valuable information on potential areas for improvement, including training, procedures, human interfaces design, and the need for automation. Modeling human error has always been a challenge in part because performance data is not always readily available. For spaceflight, the challenge is amplified not only because of the small number of participants and limited amount of performance data available, but also due to the lack of definition of the unique factors influencing human performance in space. These factors, called performance shaping factors in HRA terminology, are used in HRA techniques to modify basic human error probabilities in order to capture the context of an analyzed task. Many of the human error modeling techniques were developed within the context of nuclear power plants and therefore the methodologies do not address spaceflight factors such as the effects of microgravity and longer duration missions. This presentation will describe the types of human error risks which have shown up as risk drivers in the Shuttle PRA which may be applicable to commercial space flight. As with other large PRAs of complex machines, human error in the Shuttle PRA proved to be an important contributor (~12 percent) to LOCV. An existing HRA technique was adapted for use in the Shuttle PRA, but additional guidance and improvements are needed to make the HRA task in space-related PRAs easier and more accurate. Therefore, this presentation will also outline plans for expanding current HRA methodology to more explicitly cover spaceflight performance shaping factors.

Hamlin, Teri↗

NASA NTRS2008

Failure of the Trailing Umbilical System Disconnect Actuator on the International Space Station

In December of 2005, one of two trailing umbilical cables used on the International Space Station (ISS) Mobile Transporter (MT) was inadvertently severed by an internal cutter system designed to free a snagged cable or jammed reel while transporting hazardous payloads. The mechanism s intended means of actuation is electrical; however, troubleshooting revealed a mechanical actuation occurred. The investigation of the failed component revealed several lessons learned in developing hardware requirements, understanding and following the rationale behind the requirements throughout the design life cycle, understanding the impacts of gaps and tolerances in a mechanism, and the importance of identifying critical steps during assembly.

Gilmore, Adam↗

NASA NTRS2008

Failure of the Trailing Umbilical System Disconnect Actuator on the International Space Station

Gilmore, Adam↗