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At least 1,135 records · Page 63

Gearbox Reliability Collaborative Phase 3 Gearbox 2 Test

The National Renewable Energy Laboratory (NREL) Gearbox Reliability Collaborative (GRC) was established by the U.S. Department of Energy in 2006; its key goal is to understand the root causes of premature gearbox failures and improve their reliability. The GRC uses a combined gearbox testing, modeling, and analysis approach disseminating data and results to the industry and facilitating improvement of gearbox reliability. This test data describes the tests of GRC gearbox 2 in the National Wind Technology Center dynamometer and documents any modifications to the original test plan. It serves as a guide to interpret the publicly released data sets with brief analyses to illustrate the data. TDMS viewer and Solidworks software required to view data files.

17 WIND ENERGY↗

Impact Damage and Strain Rate Effects for Toughened Epoxy Composite Structures

Structural integrity of composite systems under dynamic impact loading is investigated herein. The GENOA virtual testing software environment is used to implement the effects of dynamic loading on fracture progression and damage tolerance. Combinations of graphite and glass fibers with a toughened epoxy matrix are investigated. The effect of a ceramic coating for the absorption of impact energy is also included. Impact and post impact simulations include verification and prediction of (1) Load and Impact Energy, (2) Impact Damage Size, (3) Maximum Impact Peak Load, (4) Residual Strength, (5) Maximum Displacement, (6) Contribution of Failure Modes to Failure Mechanisms, (7) Prediction of Impact Load Versus Time, and (8) Damage, and Fracture Pattern. A computer model is utilized for the assessment of structural response, progressive fracture, and defect/damage tolerance characteristics. Results show the damage progression sequence and the changes in the structural response characteristics due to dynamic impact. The fundamental premise of computational simulation is that the complete evaluation of composite fracture requires an assessment of ply and subply level damage/fracture processes as the structure is subjected to loads. Simulation results for the graphite/epoxy composite were compared with the impact and tension failure test data, correlation and verification was obtained that included: (1) impact energy, (2) damage size, (3) maximum impact peak load, (4) residual strength, (5) maximum displacement, and (6) failure mechanisms of the composite structure.

Chamis, Christos C.↗

Reliability-Based Design Optimization of a Composite Airframe Component

A stochastic design optimization methodology (SDO) has been developed to design components of an airframe structure that can be made of metallic and composite materials. The design is obtained as a function of the risk level, or reliability, p. The design method treats uncertainties in load, strength, and material properties as distribution functions, which are defined with mean values and standard deviations. A design constraint or a failure mode is specified as a function of reliability p. Solution to stochastic optimization yields the weight of a structure as a function of reliability p. Optimum weight versus reliability p traced out an inverted-S-shaped graph. The center of the inverted-S graph corresponded to 50 percent (p = 0.5) probability of success. A heavy design with weight approaching infinity could be produced for a near-zero rate of failure that corresponds to unity for reliability p (or p = 1). Weight can be reduced to a small value for the most failure-prone design with a reliability that approaches zero (p = 0). Reliability can be changed for different components of an airframe structure. For example, the landing gear can be designed for a very high reliability, whereas it can be reduced to a small extent for a raked wingtip. The SDO capability is obtained by combining three codes: (1) The MSC/Nastran code was the deterministic analysis tool, (2) The fast probabilistic integrator, or the FPI module of the NESSUS software, was the probabilistic calculator, and (3) NASA Glenn Research Center s optimization testbed CometBoards became the optimizer. The SDO capability requires a finite element structural model, a material model, a load model, and a design model. The stochastic optimization concept is illustrated considering an academic example and a real-life raked wingtip structure of the Boeing 767-400 extended range airliner made of metallic and composite materials.

Patnaik, Surya N.↗

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.↗

SMART: A Propositional Logic-Based Trade Analysis and Risk Assessment Tool for a Complex Mission

This paper introduces a new trade analysis software called the Space Mission Architecture and Risk Analysis Tool (SMART). This tool supports a high-level system trade study on a complex mission, such as a potential Mars Sample Return (MSR) mission, in an intuitive and quantitative manner. In a complex mission, a common approach to increase the probability of success is to have redundancy and prepare backups. Quantitatively evaluating the utility of adding redundancy to a system is important but not straightforward, particularly when the failure of parallel subsystems are correlated.

Ono, Masahiro↗

Reliability Analysis for AFTI-F16 SRFCS Using ASSIST and SURE

This paper reports the results of a study on reliability analysis of an AFTI-16 Self-Repairing Flight Control System (SRFCS) using software tools SURE (Semi-Markov Unreliability Range Evaluator and ASSIST (Abstract Semi-Markov Specification Interface to the SURE Tool). The purpose of the study is to investigate the potential utility of the software tools in the ongoing effort of the NASA Aviation Safety Program, where the class of systems must be extended beyond the originally intended serving class of electronic digital processors. The study concludes that SURE and ASSIST are applicable to reliability, analysis of flight control systems. They are especially efficient for sensitivity analysis that quantifies the dependence of system reliability on model parameters. The study also confirms an earlier finding on the dominant role of a parameter called a failure coverage. The paper will remark on issues related to the improvement of coverage and the optimization of redundancy level.

Wu, N. Eva↗

SEU/SET Tolerant Phase-Locked Loops

The phase-locked loop (PLL) is an old and widely used circuit for frequency and phase demodulation, carrier and clock recovery, and frequency synthesis [1]. Its implementations range from discrete components to fully integrated circuits and even to firmware or software. Often the PLL is a highly critical component of a system, as for example when it is used to derive the on-chip clock, but as of this writing no definitive single-event upset (SET)/single-event transient (SET) tolerant PLL circuit has been described. This chapter hopes to rectify that situation, at least in regard to PLLs that are used to generate clocks. Older literature on fault-tolerant PLLs deals with detection of a hard failure, which is recovered by replacement, repair, or manual restart of discrete component systems. Several patents exist along these lines (6349391, 6272647, and 7089442). A newer approach is to harden the parts of a PLL system, to one degree or another, such as by using a voltage-based charge pump or a triple modular redundant (TMR) voted voltage-controlled oscillator (VCO). A more comprehensive approach is to harden by triplication and voting (TMR) all the digital pieces (primarily the divider) of a frequency synthesis PLL, but this still leaves room for errors in the VCO and the loop filter. Instead of hardening or voting pieces of a system, such as a frequency synthesis system (i.e., clock multiplier), we will show how the entire system can be voted. There are two main ways of doing this, each with advantages and drawbacks. We will show how each has advantages in certain areas, depending on the lock acquisition and tracking characteristics of the PLL. Because of this dependency on PLL characteristics, we will briefly revisit the theory of PLLs. But first we will describe the characteristics of voters and their correct application, as some literature does not follow the voting procedure that guarantees elimination of errors. Additionally, we will find that voting clocks is a bit trickier than voting data where an infallible clock is assumed. It is our job here to produce (or recover) that assumed infallible clock!

Shuler, Robert L., Jr.↗

Material Characterization and Geometric Segmentation of a Composite Structure Using Microfocus X-Ray Computed Tomography Image-Based Finite Element Modeling

This study utilizes microfocus x-ray computed tomography (CT) slice sets to model and characterize the damage locations and sizes in thermal protection system materials that underwent impact testing. ScanIP/FE software is used to visualize and process the slice sets, followed by mesh generation on the segmented volumetric rendering. Then, the local stress fields around several of the damaged regions are calculated for realistic mission profiles that subject the sample to extreme temperature and other severe environmental conditions. The resulting stress fields are used to quantify damage severity and make an assessment as to whether damage that did not penetrate to the base material can still result in catastrophic failure of the structure. It is expected that this study will demonstrate that finite element modeling based on an accurate three-dimensional rendered model from a series of CT slices is an essential tool to quantify the internal macroscopic defects and damage of a complex system made out of thermal protection material. Results obtained showing details of segmented images; three-dimensional volume-rendered models, finite element meshes generated, and the resulting thermomechanical stress state due to impact loading for the material are presented and discussed. Further, this study is conducted to exhibit certain high-caliber capabilities that the nondestructive evaluation (NDE) group at NASA Glenn Research Center can offer to assist in assessing the structural durability of such highly specialized materials so improvements in their performance and capacities to handle harsh operating conditions can be made.

Abdul-Aziz, Ali↗

X-57 Traction Power and Command Systems Development

This paper describes the final, as-built design of the X‑57 Maxwell aircraft power and command system architecture that implements the electrified propulsion capability. The development of the traction power, command, and avionics power subsystems proceeded as planned at the initial project critical design review, but improvements to the design were identified following the development of detailed operations concepts and integrated subsystem and system testing. The redundant architecture with A‑side and B‑side buses provided a robust framework for a developmental system that would turn out to have a lower technology readiness than had been assumed upon project formulation. As the project team identified reliability or performance gaps in the electrified propulsion powertrain components and their interactions with the other vehicle systems, the traction power, command, and avionics architectures were modified to accommodate the modified systems. Following the publication of the planned design approach at the critical design review milestone [1], the project team developed the flight hardware and software, integrated the systems, and adjusted the design and qualification activities to address gaps in the components, system architecture, and requirements as the gaps were realized. In addition to inherent challenges in development of these subsystems, the integration of this new technology with adjacent critical systems in an aircraft configuration posed additional challenges that drove design considerations across the subsystem development and the other vehicle systems. Integration complications included electromagnetic compatibility, thermal performance, and tolerance of single-point failures internal and external to the powerplant. Development of a qualification program was required for the new motors, inverters, and batteries, and hardware performance during component qualification fed back into the development process and led lessons learned and redesign of key elements.

distributed propulsion↗

Generating Test Templates via Automated Theorem Proving

Testing can be used during the software development process to maintain fidelity between evolving specifications, program designs, and code implementations. We use a form of specification-based testing that employs the use of an automated theorem prover to generate test templates. A similar approach was developed using a model checker on state-intensive systems. This method applies to systems with functional rather than state-based behaviors. This approach allows for the use of incomplete specifications to aid in generation of tests for potential failure cases. We illustrate the technique on the cannonical triangle testing problem and discuss its use on analysis of a spacecraft scheduling system.

Kancherla, Mani Prasad↗

Probabilistic Risk Assessment of Aging Layered Pressure Vessels

The National Aeronautics and Space Administration (NASA) operates approximately 300 aging layered pressure vessels that were designed and manufactured prior to ASME Boiler and Pressure Vessel (B&PV) code requirements. In order to make decisions regarding the continued fitness-for-service of these non-code carbon steel vessels, it is necessary to perform a relative risk of failure assessment for each vessel. However, risk assessment of these vessels is confounded by uncertainties and variabilities related to the use of proprietary materials in fabrication, missing construction records, geometric discontinuities, weld residual stresses, and complex service stress gradients in and around the welds. Therefore, a probabilistic framework that can capture these uncertainties and variabilities has been developed to assess the fracture risk of flaws in regions of interest, such as longitudinal and circumferential welds, using the NESSUS® probabilistic modeling software and NASGRO® fracture mechanics software. In this study, the probabilistic framework was used to predict variability in the stress intensity factor associated with different reference flaws located in the head-to-shell circumferential welds of a 4-layer and 14-layer pressure vessel. The probabilistic studies predict variability in flaw behavior and the important uncertain parameters for each reference flaw location.

Riha, D. S.↗

The Voyager Interstellar Mission

The Voyager Interstellar Mission began on January 1, 1990, with the primary objective being to characterize the interplanetary medium beyond Neptune and to search for the transition region between the interplanetary medium and the interstellar medium. At the start of this mission, the two Voyager spacecraft had already been in flight for over twelve years, having successfully returned a wealth of scientific information about the planetary systems of Jupiter, Saturn, Uranus, and Neptune, and the interplanetary medium between Earth and Neptune. The two spacecraft have the potential to continue returning science data until around the year 2020. With this extended operating lifetime, there is a high likelihood of one of the two spacecraft penetrating the termination shock and possibly the heliopause boundary, and entering interstellar space before that time. This paper describes the Voyager Interstellar Mission--the mission objectives, the spacecraft and science payload, the mission operations system used to support operations, and the mission operations strategy being used to maximize science data return even in the event of certain potential spacecraft subsystem failures. The implementation of automated analysis tools to offset and enable reduced flight team staffing levels is also discussed.

Flight Experiment↗

Fatigue damage modeling for coated single crystal superalloys

A high temperature, low-cycle fatigue life prediction method for coated single crystal nickel-base superalloys is being developed. The method is being developed for use in predicting crack initiation life of coated single crystal turbine airfoils. Although the models are being developed using coated single crystal PWA 1480, they should be readily adaptable to other coated nickel-base single crystal materials. The coatings choosen for this effort were of two generic types: a low pressure plasma sprayed NiCoCrAlY overlay, designated PWA 286, and an aluminide diffusion, designated PWA 273. In order to predict the useful crack initiation life of airfoils, the constitutive and failure behavior of the coating/substrate combination must be taken into account. Coatings alter the airfoil surface microstructure and are a primary source from which cracks originate. The adopted life prediction approach addresses this complexity by separating the coating and single crystal crack initiation regimes. This provides a flexible means for using different life model formulations for the coating and single crystal materials. At the completion of this program, all constitutive and life model formulations will be available in equation form and as software. The software will use the MARC general purpose finite element code to drive the constitutive models and calculate life parameters.

Nissley, David M.↗

ESTAR Measurements During SGP-99

The synthetic aperture radiometer, ESTAR, provided L-band brightness temperature maps of the experiment site during the Southern Great Plains Experiment in 1999. ESTAR flew on the NASA P-3 aircraft at an altitude of 7.6 km and mapped a swath about 50 km wide and about 300 km long. The area mapped extended west from Oklahoma City to El Reno and north from the Little Washita River watershed to the Kansas border. The flight lines and mapping were done in a manner similar to that used in 1997 during SGP-97. ESTAR is a prototype designed to develop the technology of aperture synthesis for passive microwave remote sensing. It is actually a hybrid that uses real aperture to obtain resolution along track and synthetic aperture to obtain resolution across track. ESTAR operates in the band at 1.413 GHz set aside for passive use and images at horizontal polarization in the equivalent of a cross-track scan. The scan is done in software as part of image reconstruction. Calibration consists of blackbody observed before and after each flight and a local body of water (Lake Kaw). ESTAR arrived in Oklahoma on July 7, 1999 and flew mapping missions on July 8,9, 11, 14, 15, 19 and 20. The aircraft was down on July 10 by design and was down again on July 12-13 and 16-18 due to mechanical problems. ESTAR data for July I I is questionable because of a hardware failure. The brightness temperature maps reflect the patterns of soil moisture observed in the SGP99 study area and compare well with measurements made by ESTAR in other experiments in this region (e.g. SGP -97 and Washita-92).

LeVine, D. M.↗

Testing of the on-board attitude determination and control algorithms for SAMPEX

Algorithms for on-board attitude determination and control of the Solar, Anomalous, and Magnetospheric Particle Explorer (SAMPEX) have been expanded to include a constant gain Kalman filter for the spacecraft angular momentum, pulse width modulation for the reaction wheel command, an algorithm to avoid pointing the Heavy Ion Large Telescope (HILT) instrument boresight along the spacecraft velocity vector, and the addition of digital sun sensor (DSS) failure detection logic. These improved algorithms were tested in a closed-loop environment for three orbit geometries, one with the sun perpendicular to the orbit plane, and two with the sun near the orbit plane - at Autumnal Equinox and at Winter Solstice. The closed-loop simulator was enhanced and used as a truth model for the control systems' performance evaluation and sensor/actuator contingency analysis. The simulations were performed on a VAX 8830 using a prototype version of the on-board software.

Mccullough, Jon D.↗

Airport Simulations Using Distributed Computational Resources

The Virtual National Airspace Simulation (VNAS) will improve the safety of Air Transportation. In 2001, using simulation and information management software running over a distributed network of super-computers, researchers at NASA Ames, Glenn, and Langley Research Centers developed a working prototype of a virtual airspace. This VNAS prototype modeled daily operations of the Atlanta airport by integrating measured operational data and simulation data on up to 2,000 flights a day. The concepts and architecture developed by NASA for this prototype are integral to the National Airspace Simulation to support the development of strategies improving aviation safety, identifying precursors to component failure.

McDermott, William J.↗

A surface ice module for wind turbine dynamic response simulation using FAST

It is a fact that developing offshore wind energy has become more and more serious worldwide in recent years. Many of the promising offshore wind farm locations are in cold regions that may have ice cover during wintertime. The challenge of possible ice loads on offshore wind turbines raises the demand of modeling capacity of dynamic wind turbine response under the joint action of ice, wind, wave, and current. The simulation software FAST is an open source computer-aided engineering (CAE) package maintained by the National Renewable Energy Laboratory. In this paper, a new module of FAST for assessing the dynamic response of offshore wind turbines subjected to ice forcing is presented. In the ice module, several models are presented which involve both prescribed forcing and coupled response. For conditions in which the ice forcing is essentially decoupled from the structural response, ice forces are established from existing models for brittle and ductile ice failure. For conditions in which the ice failure and the structural response are coupled, such as lock-in conditions, a rate-dependent ice model is described, which is developed in conjunction with a new modularization framework for FAST. In this paper, analytical ice mechanics models are presented that incorporate ice floe forcing, deformation, and failure. For lower speeds, forces slowly build until the ice strength is reached and ice fails resulting in a quasi-static condition. For intermediate speeds, the ice failure can be coupled with the structural response and resulting in coinciding periods of the ice failure and the structural response. A third regime occurs at high speeds of encounter in which brittle fracturing of the ice feature occurs in a random pattern, which results in a random vibration excitation of the structure. An example wind turbine response is simulated under ice loading of each of the presented models. This module adds to FAST the capabilities for analyzing the response of wind turbines subjected to forces resulting from ice impact on the turbine support structure. The conditions considered in this module are specifically addressed in the International Organization for Standardization (ISO) standard 19906:2010 for arctic offshore structures design consideration. Special consideration of lock-in vibrations is required due to the detrimental effects of such response with regard to fatigue and foundation/soil response. Finally, the use of FAST for transient, time domain simulation with the new ice module is well suited for such analyses.

17 WIND ENERGY↗

Software fault-tolerance by design diversity DEDIX: A tool for experiments

The use of multiple versions of a computer program, independently designed from a common specification, to reduce the effects of an error is discussed. If these versions are designed by independent programming teams, it is expected that a fault in one version will not have the same behavior as any fault in the other versions. Since the errors in the output of the versions are different and uncorrelated, it is possible to run the versions concurrently, cross-check their results at prespecified points, and mask errors. A DEsign DIversity eXperiments (DEDIX) testbed was implemented to study the influence of common mode errors which can result in a failure of the entire system. The layered design of DEDIX and its decision algorithm are described.

Avizienis, A.↗