SEARCH · Engineering Papers

Results for “hardware failure”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 865 records · Page 48

All sources NASA NTRS DOE OSTI

NASA NTRS2011

Reliability of Ceramic Column Grid Array Interconnect Packages Under Extreme Temperatures

A paper describes advanced ceramic column grid array (CCGA) packaging interconnects technology test objects that were subjected to extreme temperature thermal cycles. CCGA interconnect electronic package printed wiring boards (PWBs) of polyimide were assembled, inspected nondestructively, and, subsequently, subjected to ex - treme-temperature thermal cycling to assess reliability for future deep-space, short- and long-term, extreme-temperature missions. The test hardware consisted of two CCGA717 packages with each package divided into four daisy-chained sections, for a total of eight daisy chains to be monitored. The package is 33 33 mm with a 27 27 array of 80%/20% Pb/Sn columns on a 1.27-mm pitch. The change in resistance of the daisy-chained CCGA interconnects was measured as a function of the increasing number of thermal cycles. Several catastrophic failures were observed after 137 extreme-temperature thermal cycles, as per electrical resistance measurements, and then the tests were continued through 1,058 thermal cycles to corroborate and understand the test results. X-ray and optical inspection have been made after thermal cycling. Optical inspections were also conducted on the CCGA vs. thermal cycles. The optical inspections were conclusive; the x-ray images were not. Process qualification and assembly is required to optimize the CCGA assembly, which is very clear from the x-rays. Six daisy chains were open out of seven daisy chains, as per experimental test data reported. The daisy chains are open during the cold cycle, and then recover during the hot cycle, though some of them also opened during the hot thermal cycle..

Ramesham, Rajeshuni↗

NASA NTRS1972

Space Shuttle Avionics: a Redundant IMU On-Board Checkout and Redundancy Management System

A failure detection and isolation philosophy applicable to multiple off-the-shelf gimbaled IMUs are discussed. The equations developed are implemented and evaluated with actual shuttle trajectory simulations. The results of these simulations are presented for both powered and unpowered flight phases and at operational levels of four, three, and two IMUs. A multiple system checkout philosophy is developed and simulation results presented. The final task develops a laboratory test plan and defines the hardware and software requirements to implement an actual multiple system and evaluate the interim study results for space shuttle application.

Mckern, R. A.↗

NASA NTRS2008

Integrated Safety Analysis Teams

Today's complex systems require understanding beyond one person s capability to comprehend. Each system requires a team to divide the system into understandable subsystems which can then be analyzed with an Integrated Hazard Analysis. The team must have both specific experiences and diversity of experience. Safety experience and system understanding are not always manifested in one individual. Group dynamics make the difference between success and failure as well as the difference between a difficult task and a rewarding experience. There are examples in the news which demonstrate the need to connect the pieces of a system into a complete picture. The Columbia disaster is now a standard example of a low consequence hazard in one part of the system; the External Tank is a catastrophic hazard cause for a companion subsystem, the Space Shuttle Orbiter. The interaction between the hardware, the manufacturing process, the handling, and the operations contributed to the problem. Each of these had analysis performed, but who constituted the team which integrated this analysis together? This paper will explore some of the methods used for dividing up a complex system; and how one integration team has analyzed the parts. How this analysis has been documented in one particular launch space vehicle case will also be discussed.

Wetherholt, Jonathan C.↗

NASA NTRS2011

Adding a Second Ku-Band Antenna to the International Space Station

The International Space Station, as originally developed, used the Ku-Band Tracking and Data Relay Satellite System communications link to transmit non-critical data to the ground. Since becoming operational, the use for the link evolved to include additional services that, although also not critical, were deemed to be necessary for the crew. The external Ku-Band Antennas were designed for transport to the ISS in the shuttle cargo bay and thus are not suitable for manifesting on any current cargo vehicle. The original intent was to stow two spare antennas on orbit in a protective container until such time as they were needed to replace a failing unit which is a long and complicated process due to the complexity of the removal and replacement procedure. The Boeing Company proposed manifesting one of those spare antennas in an operable configuration eliminating the need for an Extravehicular Activity (EVA) to correct the first failure and as such minimizing the time to hours rather than weeks required to restore the Ku-Band communications link after failures. After the first failure, an EVA would be scheduled to replace the failed antenna with the stowed spare antenna. Because the hot spare is activated internal to the ISS, the replacement of the failed unit can be done when convenient rather than in haste. This paper describes the methodology used to locate a suitable site to add a new antenna mast to the ISS as well the process followed to fabricate, deliver and install the new interface hardware. Because this was not planned when the ISS was originally designed, structural, power, data and Intermediate Frequency signal connections had to be found for use. With the movement of the P6 solar array element from the initial location in the center zenith location of the ISS to the end of the port side of the truss and concurrent relocation of one string of S-Band communications assets, there were candidate power, data and structural connections available on the Z1 Truss. The engineering team evaluated these residual interfaces for use and designed cabling and structural elements for the candidate interfaces. The antenna was recently installed on ULF-4 and has completed a preliminary checkout. Included in this check out were evaluation of the power level received from the TDRS and evaluation of the gimbal position feedback for consideration in the static bias pointing matrix. This process demonstrates the ability to modify and upgrade manned space vehicles as either need or technology requires.

DuSold, Chuck↗

NASA NTRS1991

Proximity operations considerations affecting spacecraft design

Proximity operations can be defined as the maneuvering of two or more spacecraft within 1 nautical mile range, with relative velocity less than 10 feet per second. The passive vehicle is nontranslating and should provide for maintenance of the desired approach attitude. It must accommodate the active (translating) vehicle induced structural loads and performance characteristics (mating hardware tolerances), and support sensor compatibility (transponder, visual targets, etc.). The active vehicle must provide adequate sensor systems (relative state information, field-of-view, redundancy), flight control hardware (thruster sizing, minimal cross-coupling, performance margins, redundancy) and software (reconfigurable, attitude/rate modes, translation and rotation fine control authority) characteristic, and adequate non-propulsive consumables such as power. Operational concerns must be considered. These include the following: (1) the desired approach trajectory and relative orientation; (2) the active vehicle thruster plume effects (forces, torques, contamination) on the passive vehicle; and (3) procedures for contingencies such as loss of communications, sensor or propulsion failures, and target vehicle loss of control.

Staas, Steven K.↗

NASA NTRS1972

Design and flight experience with a digital fly-by-wire control system using Apollo guidance system hardware on an F-8 aircraft.

This paper discusses the design and initial flight tests of the first digital fly-by-wire system to be flown in an aircraft. The system, which used components from the Apollo guidance system, was installed in an F-8 aircraft. A lunar module guidance computer is the central element in the three-axis, single-channel, multimode, digital, primary control system. An electrohydraulic triplex system providing unaugmented control of the F-8 aircraft is the only backup to the digital system. Emphasis is placed on the digital system in its role as a control augmentor, a logic processor, and a failure detector. A sampled-data design synthesis example is included to demonstrate the role of various analytical and simulation methods. The use of a digital system to implement conventional control laws was shown to be practical for flight. Logic functions coded as an integral part of the control laws were found to be advantageous. Verification of software required an extensive effort, but confidence in the software was achieved. Initial flight results showed highly successful system operation, although quantization of pilot's stick and trim were areas of minor concern from the piloting standpoint.

Deets, D. A.↗

NASA NTRS1986

Pulse Code Modulation (PCM) encoder handbook for Aydin Vector MMP-600 series system

The hardware and software characteristics of a time division multiplex system are described. The system is used to sample analog and digital data. The data is merged with synchronization information to produce a serial pulse coded modulation (PCM) bit stream. Information presented herein is required by users to design compatible interfaces and assure effective utilization of this encoder system. GSFC/Wallops Flight Facility has flown approximately 50 of these systems through 1984 on sounding rockets with no inflight failures. Aydin Vector manufactures all of the components for these systems.

Currier, S. F.↗

NASA NTRS1992

Validation test of advanced technology for IPV nickel-hydrogen flight cells: Update

Individual pressure vessel (IPV) nickel-hydrogen technology was advanced at NASA Lewis and under Lewis contracts with the intention of improving cycle life and performance. One advancement was to use 26 percent potassium hydroxide (KOH) electrolyte to improve cycle life. Another advancement was to modify the state-of-the-art cell design to eliminate identified failure modes. The modified design is referred to as the advanced design. A breakthrough in the low-earth-orbit (LEO) cycle life of IPV nickel-hydrogen cells has been previously reported. The cycle life of boiler plate cells containing 26 percent KOH electrolyte was about 40,000 LEO cycles compared to 3,500 cycles for cells containing 31 percent KOH. The boiler plate test results are in the process of being validated using flight hardware and real time LEO testing at the Naval Weapons Support Center (NWSC), Crane, Indiana under a NASA Lewis Contract. An advanced 125 Ah IPV nickel-hydrogen cell was designed. The primary function of the advanced cell is to store and deliver energy for long-term, LEO spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent KOH electrolyte; (2) use of a patented catalyzed wall wick; (3) use of serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management; and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion due to charge/discharge cycling. The significant improvements resulting from these innovations are: extended cycle life; enhanced thermal, electrolyte, and oxygen management; and accommodation of nickel electrode expansion. The advanced cell design is in the process of being validated using real time LEO cycle life testing of NWSC, Crane, Indiana. An update of validation test results confirming this technology is presented.

Smithrick, John J.↗

NASA NTRS2021

Damage Tolerance of Candidate Sandwich Structure for the Space Launch System (SLS) Payload Adapter Fitting (PAF)

This Technical Memorandum presents results from a damage tolerance study undertaken in support of the payload adapter fitting (PAF) for the Space Launch System (SLS) program at NASA’s Marshall Space Flight Center (MSFC). The study consisted of determining the compression-after-impact (CAI) strength of candidate carbon/epoxy face sheet sandwich structure that has been identified for potential use to manufacture the PAF hardware. Two types of core material that have been considered for use on the PAF structure were used in this study. One was an aluminum honeycomb and the other was a Rohacell foam. Levels of barely visible impact damage (BVID) were determined for the types of sandwich structure tested in this study and this level of damage was used for CAI strength testing. It was found that the honeycomb core sandwich structure failed by face sheet failure and the foam core sandwich structure failed by core shear failure. CAI strength values were normalized by weight of the sandwich structure since lower mass is desirable for this structure.

sandwich structure↗

NASA NTRS1986

Advanced Gas Turbine (AGT) Technology Project

Engine testing, ceramic component fabrication and evaluation, component performance rig testing, and analytical studies comprised AGT 100 activities during the 1985 year. Ten experimental assemblies (builds) were evaluated using two engines. Accrued operating time was 120 hr of burning and 170 hr total, bringing cumulative total operating time to 395 hr, all devoid of major failures. Tests identified the generator seals as the primary working fluid leakage sources. Power transfer clutch operation was demonstrated. An alpha SiC gasifier rotor engine test resulted in blade tip failures. Recurring case vibration and shaft whip have limited gasifier shaft speeds to 84%. Ceramic components successfully engine tested now include the SiC scroll assembly, Si3N3 turbine rotor, combustor assembly, regenerator disk bulkhead, turbine vanes, piston rings, and couplings. A compressor shroud design change to reduce heat recirculation back to the inlet was executed. Ceramic components activity continues to focus on the development of state-of-the-art material strength characteristics in full-scale engine hardware. Fiber reinforced glass-ceramic composite turbine (inner) backplates were fabricated by Corning Glass Works. The BMAS/III material performed well in engine testing. Backplates of MAS material have not been engine tested.

Source record↗

NASA NTRSDate not supplied

Runtime Verification with Ogma

Ultra-critical systems require high-level assurance, which cannot always be guaranteed in compile time. The use of runtime verification (RV) enable monitoring these systems in runtime, to detect property violations early and limit their potential consequences. However, the introduction of monitors in ultra-critical systems poses a challenge, as failures and delays in the RV subsystem could affect other subsystems and threaten the mission as a whole. In this talk we discuss two systems: NASA's Ogma, a tool to transform high-level specifications into monitoring code, and Copilot, a runtime verification framework for real-time embedded systems. The toolchain can be used to translate structured natural language requirements into C code with static memory requirements, which can be compiled to run on embedded hardware.

Ogma↗

NASA NTRSDate not supplied

Runtime Verification with Ogma

Ogma↗

NASA NTRS1973

Sensitivity of a critical tracking task to alcohol impairment

A first order critical tracking task is evaluated for its potential to discriminate between sober and intoxicated performances. Mean differences between predrink and postdrink performances as a function of BAC are analyzed. Quantification of the results shows that intoxicated failure rates of 50% for blood alcohol concentrations (BACs) at or above 0.1%, and 75% for BACs at or above 0.14%, can be attained with no sober failure rates. A high initial rate of learning is observed, perhaps due to the very nature of the task whereby the operator is always pushed to his limit, and the scores approach a stable asymptote after approximately 50 trials. Finally, the implementation of the task as an ignition interlock system in the automobile environment is discussed. It is pointed out that lower critical performance limits are anticipated for the mechanized automotive units because of the introduction of larger hardware and neuromuscular lags. Whether such degradation in performance would reduce the effectiveness of the device or not will be determined in a continuing program involving a broader based sample of the driving population and performance correlations with both BACs and driving proficiency.

Tennant, J. A.↗

NASA NTRS1985

Mathematical models for space shuttle ground systems

Math models are a series of algorithms, comprised of algebraic equations and Boolean Logic. At Kennedy Space Center, math models for the Space Shuttle Systems are performed utilizing the Honeywell 66/80 digital computers, Modcomp II/45 Minicomputers and special purpose hardware simulators (MicroComputers). The Shuttle Ground Operations Simulator operating system provides the language formats, subroutines, queueing schemes, execution modes and support software to write, maintain and execute the models. The ground systems presented consist primarily of the Liquid Oxygen and Liquid Hydrogen Cryogenic Propellant Systems, as well as liquid oxygen External Tank Gaseous Oxygen Vent Hood/Arm and the Vehicle Assembly Building (VAB) High Bay Cells. The purpose of math modeling is to simulate the ground hardware systems and to provide an environment for testing in a benign mode. This capability allows the engineers to check out application software for loading and launching the vehicle, and to verify the Checkout, Control, & Monitor Subsystem within the Launch Processing System. It is also used to train operators and to predict system response and status in various configurations (normal operations, emergency and contingent operations), including untried configurations or those too dangerous to try under real conditions, i.e., failure modes.

Tory, E. G.↗

NASA NTRS1991

Design for Validation

The use of computer hardware and software in life-critical applications, such as for civil air transports, demands the use of rigorous formal mathematical validation procedures. However, formal specification and verification will only be tractable if the system is designed in a manner that lends itself to formal methods. Likewise, accurate reliability analysis will only be tractable if the number of interacting components that must be individually included in a single reliability model is kept to a low number and if their failure behavior interactions can be modeled simply. Also, the system must be designed such that the system reliability does not directly depend on system parameters that cannot be accurately determined. This paper presents a design methodology based on the concept of designing a system in such a manner that it can be rigorously validated, or "design for validation."

Johnson, Sally C.↗

NASA NTRS2009

Sensor Data Qualification System (SDQS) Implementation Study

The Sensor Data Qualification System (SDQS) is being developed to provide a sensor fault detection capability for NASA s next-generation launch vehicles. In addition to traditional data qualification techniques (such as limit checks, rate-of-change checks and hardware redundancy checks), SDQS can provide augmented capability through additional techniques that exploit analytical redundancy relationships to enable faster and more sensitive sensor fault detection. This paper documents the results of a study that was conducted to determine the best approach for implementing a SDQS network configuration that spans multiple subsystems, similar to those that may be implemented on future vehicles. The best approach is defined as one that most minimizes computational resource requirements without impacting the detection of sensor failures.

Wong, Edmond↗

NASA NTRS2015

Reliability and Probabilistic Risk Assessment - How They Play Together

PRA methodology is one of the probabilistic analysis methods that NASA brought from the nuclear industry to assess the risk of LOM, LOV and LOC for launch vehicles. PRA is a system scenario based risk assessment that uses a combination of fault trees, event trees, event sequence diagrams, and probability and statistical data to analyze the risk of a system, a process, or an activity. It is a process designed to answer three basic questions: What can go wrong? How likely is it? What is the severity of the degradation? Since 1986, NASA, along with industry partners, has conducted a number of PRA studies to predict the overall launch vehicles risks. Planning Research Corporation conducted the first of these studies in 1988. In 1995, Science Applications International Corporation (SAIC) conducted a comprehensive PRA study. In July 1996, NASA conducted a two-year study (October 1996 - September 1998) to develop a model that provided the overall Space Shuttle risk and estimates of risk changes due to proposed Space Shuttle upgrades. After the Columbia accident, NASA conducted a PRA on the Shuttle External Tank (ET) foam. This study was the most focused and extensive risk assessment that NASA has conducted in recent years. It used a dynamic, physics-based, integrated system analysis approach to understand the integrated system risk due to ET foam loss in flight. Most recently, a PRA for Ares I launch vehicle has been performed in support of the Constellation program. Reliability, on the other hand, addresses the loss of functions. In a broader sense, reliability engineering is a discipline that involves the application of engineering principles to the design and processing of products, both hardware and software, for meeting product reliability requirements or goals. It is a very broad design-support discipline. It has important interfaces with many other engineering disciplines. Reliability as a figure of merit (i.e. the metric) is the probability that an item will perform its intended function(s) for a specified mission profile. In general, the reliability metric can be calculated through the analyses using reliability demonstration and reliability prediction methodologies. Reliability analysis is very critical for understanding component failure mechanisms and in identifying reliability critical design and process drivers. The following sections discuss the PRA process and reliability engineering in detail and provide an application where reliability analysis and PRA were jointly used in a complementary manner to support a Space Shuttle flight risk assessment.

Safie, Fayssal M.↗

NASA NTRSDate not supplied

Testing and Analysis Correlation of a Large-Scale Composite Sandwich Longitudinal Bonded Joint for Space Launch Vehicle Structures

The NASA Composite Technology for Exploration (CTE) Project is developing and demonstrating critical composite technologies with a focus on composite bonded joints; incorporating materials, design/analysis, manufacturing, and tests that utilize NASA’s expertise and capabilities. The project has goals of advancing composite technologies and providing lightweight structures to support future NASA exploration missions. In particular, the CTE project will demonstrate weight-saving, performance-enhancing composite bonded joint technology for Space Launch System (SLS)-scale composite hardware. Advancements from the CTE project may be incorporated as future block upgrades for SLS structural components. This paper discusses the details of the development of a composite sandwich bonded longitudinal joint for a generic space launch vehicle structure called the CTE Point Design. This paper reports on the large-scale longitudinal bonded joint test articles that were fabricated and tested under axial compressive loading conditions to test the capability of the bonded joint design for buckling and joint failure. Test and analysis correlation of an as-manufactured undamaged longitudinal bonded joint panel are presented in the paper for tests to the onset of buckling and panel failure. Analysis predictions for buckling initiation and panel failure were both within 10% of the longitudinal bonded joint panel test results. This testing and analysis provide confidence in the potential use of composite bonded joints for future launch vehicle structures.

David W Sleight↗