SEARCH · Engineering Papers
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Probabilistic modeling and stochastic process investigations to provide measures of quality of performance and reliability for systems engineering - Chebyshev approximation
Leaks on the Space Shuttle while on the Launch Pad have generated interest in hydrogen leak monitoring technology. An effective leak monitoring system requires reliable hydrogen sensors, hardware, and software to monitor the sensors. The system should process the sensor outputs and provide real-time leak monitoring information to the operator. This paper discusses the progress in developing such a complete leak monitoring system. Advanced microfabricated hydrogen sensors are being fabricated at Case Western Reserve University (CWRU) and tested at NASA Lewis Research Center (LeRC) and Gencorp Aerojet (Aerojet). Changes in the hydrogen concentrations are detected using a PdAg on silicon Schottky diode structure. Sensor temperature control is achieved with a temperature sensor and heater fabricated onto the sensor chip. Results of the characterization of these sensors are presented. These sensors can detect low concentrations of hydrogen in inert environments with high sensitivity and quick response time. Aerojet is developing the hardware and software for a multipoint leak monitoring system designed to provide leak source and magnitude information in real time. The monitoring system processes data from the hydrogen sensors and presents the operator with a visual indication of the leak location and magnitude. Work has commenced on integrating the NASA LeRC-CWRU hydrogen sensors with the Aerojet designed monitoring system. Although the leak monitoring system was designed for hydrogen propulsion systems, the possible applications of this monitoring system are wide ranged. Possible commercialization of the system will also be discussed.
The goal of this NASA-funded research is to advance research and education objectives in theoretical and computational probabilistic structural analysis, reliability, and life prediction methods for improved aerospace and aircraft propulsion system components. Reliability methods are used to quantify response uncertainties due to inherent uncertainties in design variables. In this report, several reliability methods are applied to a series pipe network. The observed responses are the head delivered by a main pump and the line head at a desired flow rate. The probability that the flow rate in the line will be less than a specified minimum will be discussed.
The goal of this NASA-funded research is to advance research and education objectives in theoretical and computational probabilistic structural analysis, reliability, and life prediction methods for improved aerospace and aircraft propulsion system components. Reliability methods are used to quantify response uncertainties due to inherent uncertainties in design variables. In this report, several reliability methods are applied to a parallel pipe network. The observed responses are the head delivered by a main pump and the head values of two parallel lines at certain flow rates. The probability that the flow rates in the lines will be less than their specified minimums will be discussed.
The paper describes an approach to the integration of qualitative and quantitative modeling techniques for advanced life support (ALS) systems. Developing reliable control strategies that scale up to fully integrated life support systems requires augmenting quantitative models and control algorithms with the abstractions provided by qualitative, symbolic models and their associated high-level control strategies. This will allow for effective management of the combinatorics due to the integration of a large number of ALS subsystems. By focusing control actions at different levels of detail and reactivity we can use faster: simpler responses at the lowest level and predictive but complex responses at the higher levels of abstraction. In particular, methods from model-based planning and scheduling can provide effective resource management over long time periods. We describe reference implementation of an advanced control system using the IDEA control architecture developed at NASA Ames Research Center. IDEA uses planning/scheduling as the sole reasoning method for predictive and reactive closed loop control. We describe preliminary experiments in planner-based control of ALS carried out on an integrated ALS simulation developed at NASA Johnson Space Center.
A document describes a system to reliably gather the hang-angle inclination of the orbiter. The system comprises a wireless handheld master station (which contains the main station software) and a wireless remote station (which contains the inclinometer sensors, the RF transceivers, and the remote station software). The remote station is designed to provide redundancy to the system. It includes two RF transceivers, two power-management boards, and four inclinometer sensors.
As the outlook for space exploration becomes more ambitious and spacecraft travel deeper into space than ever before, it is increasingly important that propulsion systems perform reliably within the space environment. The increased reliability compels designers to increase design margin at the expense of system mass, which contrasts with the need to limit vehicle mass to maximize payload. Such are the factors that motivate the integration of high specific strength composite materials in the construction of pressure vessels commonly referred to as composite overwrapped pressure vessels (COPV). The COPV consists of a metallic liner for the inner shell of the COPV that is stiff, negates fluid permeation and serves as the anchor for composite laminates or filaments, but the liner itself cannot contain the stresses from the pressurant it contains. The compo-site-fiber reinforced polymer (CFRP) is wound around the liner using a combination of hoop (circumferential) and helical orientations. Careful consideration of wrap orientation allows the composite to evenly bear structural loading and creates the COPV's characteristic high strength to weight ratio. As the CFRP overwrap carries most of the stresses induced by pressurization, damage to the overwrap can affect mission duration, mission success and potentially cause loss-of-vehicle/loss-of-crew. For this reason, it is critical to establish a fundamental understanding of the mechanisms involved in the failure of a stressed composite such as that of the COPV. One of the greatest external threats to the integrity of a spacecraft's COPV is an impact from the meteoroid and orbital debris environments (MMOD). These impacts, even from submillimeter particles, generate extremely high stress states in the CFRP that can damage numerous fibers. As a result of this possibility, initial assumptions in survivability analysis for some human-rated NASA space-craft have assumed that any alteration of the vessel due to impact is considered a catastrophic failure. This assumption is conservative and made due to lack of knowledge on the level of allow-able damage to the composite overwrap that can be sustained and still allow successful completion of the mission. To quantify the allowable damage level to the composite overwrap involves assessing stress redistribution following damage as well as evaluating possible time-dependent mechanisms involved in the COPV response to an impact event. Limited published work in this subject has shown that COPV can withstand at least some level of damage due to high energy impacts. These observations have been confirmed and expanded upon in recent experimental research performed by NASA. This research has demonstrated that there is not only robustness in a COPV to compensate for CFRP damage, but has also identified two significant failure modes for pressurized COPV. The lowest threshold failure mode involves the perforation of the vessel, and the highest threshold failure mode is the catastrophic rupture. While both of these failure modes mean a loss of the COPV, system robustness affords some tolerance to the venting as opposed to the more catastrophic rupture. As a consequence, it is necessary to understand the conditions that result in the transition between these failure modes. The aforementioned experimental research has been performed in both the unpressurized and pressurized condition to identify the damage level that triggered the failure thresh-old. This COPV test program was sponsored by the NASA Engineering and Safety Center (NESC), and tests were performed at NASA White Sands Test Facility (WSTF). Planning and coordination were provided by NASA JSC Hypervelocity Impact Technology (HVIT) group, and the COPVs were provided by the ISS Program. Unpressurized testing has been conducted at the pressure of the vacuum test chamber, while, the pressurized testing has been conducted at 290 +/- 10 bar (4,200 100 psi) using nitrogen as the pressurizing gas, which corresponds to the design pressure for the target COPV. In this research, spherical aluminum projectiles with varying diameter has been chosen as the impactor. For the unpressurized COPV, the dependence of penetration up to the dependence of hole size in the liner has been obtained as a function of impact conditions. For the pressurized research, the dependence of penetration up to rupture has been obtained as a function of im-pact conditions. Two representative post-test photographs of the failed COPV's from a nor-mal impact into the COPV surface are shown in Fig. 1. These images display the dramatic difference between failure modes, venting (Fig. 1a) and rupture (Fig. 1b). For venting, liner perforation, severed composite fibers/tows and ply delamination are commonly observed damage characteristics of this COPV failure mode. In the case of rupture, the COPV typically experienced a separation of its domed regions and severe break-up of the cylindrical region. Fully understanding the transition from venting to rupture experimentally is costly and potentially unachievable for conditions that cannot be generated in the laboratory. These shortcomings have motivated the performance of three-dimensional numerical simulations to expand the existing experimental database. These simulations have been carried out with the nonlinear-structural-dynamics, analysis-tool, CTH. A typical pressure contour plot from an impact simulation of an entire COPV is shown in Fig. 2. To generate the COPV stress state without initiating a shock wave, the pressure in the simulated COPV is ramped up to the final pressure over a millisecond prior to impact of the projectile with nitrogen gas. Figure 2a shows the system in this initial condition. After one millisecond, a projectile is initiated into the simulation and impacts the COPV. Figure 2b shows the system after this impact. In the figure, the onset of venting is represented as the change in pressure (μbar), red to green, at the perforation site. Also seen in the figure is the eroded projectile that had passed into the COPV vessel with the generated shock wave in the pressurant propagating just ahead of the material. In this paper, pertinent experimental details and the development of the material constitutive models necessary for this work along with the efforts to validate their use are dis-cussed. The simulation results are presented and compared with the NASA experimental observations. While work is on-going from this effort, early observations pertinent to the failure threshold are presented.
The National Renewable Energy Laboratory (NREL), in partnership with Wonderful Renewable Energy (WRE) and Idaho National Laboratory (INL), plans to develop a general methodology for designing integrated biorefinery solids preprocessing, handling, and feeding systems based on the chemical, physical, and mechanical attributes of the starting biomass material. This attribute-driven approach will include detailed feedstock property measurements, iterative computational modeling, and bench-scale testing to design systems for preprocessing, handling, and reactor in-feed, up to and including the selection of the conversion reactor. The initial tests and system design will be conducted using waste material from almond and pistachio growing and production operations (shells, hulls, and wood), targeting the conversion of this material to syngas for electricity production. The methodology will then be generalized to other feedstocks. The purpose of this project is to design an integrated solids handling system to maximize the process reliability of converting almond and pistachio waste to electricity. The design methodology and workflow developed from this example will then be applied to the Feedstock Conversion Interface Consortium (FCIC) benchmark loblolly pine residues, thus demonstrating the robustness of the overall design approach and providing insight and guidance for future conversion systems. V-Grid Energy Systems was brought on as a subcontractor to provide gasifiers and labor to complete gasifier runs.
Reliable and mass-efficient techniques for biocide dosing are necessary to enable residual microbial control in spacecraft potable water systems. DirectINJECT is an approach to provide residual microbial control by injection of concentrated aqueous biocide solution (e.g., highly soluble silver salt), and associated dosing systems technology developments. This would allow for well-controlled liquid biocide injection that requires low consumable mass and is insensitive to the chemistry of the target water. With a 40 g Ag+/l solution, required dosing rates would be ~1 μl/minute during water processing (for a system similar to the ISS WPA), requiring only approximately 20 ml/crew-year of concentrate. We identified and characterized the performance of three dosing systems: pressure-driven flow through a robust micro-capillary tube, a miniature peristaltic pump, and a multi-piston pump with integrated valving. We began to address several potential system reliability concerns including prevention or segregation of gas bubbles in the concentrate reservoirs as well as long-term materials compatibility and mechanical life.
Reliable and mass-efficient techniques for biocide dosing are necessary to enable residual microbial control in spacecraft potable water systems. DirectINJECT is an approach to provide ultra-low flow rate injection of stable aqueous biocide concentrate solution (e.g., highly soluble silver salt). This method has the benefit of low consumable mass and is insensitive to the chemistry of the target water. With a 40 g Ag+/liter solution, required dosing rates would be ~1 μl/minute during water processing (for a system similar to the ISS WPA), requiring only approximately 20 ml/crew-year of concentrate. The performance of three dosing systems were identified and characterized: pressure-driven flow through a robust micro-capillary tube with a solenoid valve shut-off, a miniature peristaltic pump, and a multi-piston pump with integrated valving. Several potential system reliability concerns are addressed including prevention or segregation of gas bubbles in the concentrate reservoirs as well as long-term materials compatibility and mechanical life.
The evolution of the power system to the reliable, efficient and sustainable system of the future will involve development of both demand- and supply-side technology and operations. Ambitious national and state-level goals around the decarbonization of electricity relies on the integration of very high levels of renewable resources, most of which are variable and intermittent. The use of demand response is an ideal approach to counterbalance the intermittency of renewable generation and brings the consumer into the spotlight. Until recently, very little research had been conducted on the co-optimization of these two systems due to computational limitations. However, advances in computational capabilities, and the judicious use of decomposition methods and innovative approximation methods for high-dimension dynamic programming made this goal a viable objective for this project, leading to a fundamental shift in the ability to integrate and fully utilize demand-side resources. To this end, the modeling framework developed introduces a novel co-optimization framework, to include the operations of both the transmission and distribution systems (or microgrids) in operational decision making. This framework was used to analyze renewable and distributed generation along with responsive demand and to compare the capability of co-optimized systems to perform with higher levels of variable renewables. Results show that the use of a bi-level optimization approach is an appropriate structure, capable of co-optimizing a transmission system with multiple distribution systems and microgrids. While increasing the number of connected systems provides increasing flexibility for renewables integration this can also the economic benefits to the low-voltage subsystems with each additional system connected. Comparison of a traditional single-level decision structure with the co-optimization approach illustrates a reduction in overall system cost under co-optimization, while specific cost allocations to transmission and distribution systems are changed.
The evolution of the power system to the reliable, efficient and sustainable system of the future will involve development of both demand- and supply-side technology and operations. Ambitious national and state-level goals around the decarbonization of electricity relies on the integration of very high levels of renewable resources, most of which are variable and intermittent. The use of demand response is an ideal approach to counterbalance the intermittency of renewable generation and brings the consumer into the spotlight. Though individual consumers are interconnected at the low-voltage distribution system, these resources are typically modeled as variables at the transmission network level. Demand-side participation cannot be leveraged effectively without explicitly including the distribution system dynamics in the optimization-based wholesale market operations. This project grew from a vision for co-optimized interaction of distribution systems, or microgrids, with the high-voltage transmission system. In this framework, microgrids encompass consumers, distributed renewables and storage. The energy management system of the lower voltage system (distribution or microgrid) can also sell (buy) excess (necessary) energy from the transmission system. Until recently, very little research had been conducted on the co-optimization of these two systems due to computational limitations. However, advances in computational capabilities, and the judicious use of decomposition methods and innovative approximation methods for high-dimension dynamic programming made this goal a viable objective for this project, leading to a fundamental shift in the ability to integrate and fully utilize demand-side resources. To this end, the modeling framework developed introduces a novel co-optimization framework, to include the operations of both the transmission and distribution systems (or microgrids) in operational decision making. This framework was used to analyze renewable and distributed generation along with responsive demand and to compare the capability of co-optimized systems to perform with higher levels of variable renewables. An ideal microgrid is defined as an electric entity capable of operating in both interconnected (with the high-voltage grid) and islanded mode. As such, the microgrid should incorporate generating units (traditional units and intermittent) and if needed, exchange power with the high-voltage grid. The interplay between the microgrid and high-voltage grid motivated the development of the co-optimization approach to ensure efficient performance of the interconnected network. Results show that the use of a bi-level optimization approach is an appropriate structure, capable of co-optimizing a transmission system with multiple distribution systems and microgrids. While increasing the number of connected systems provides increasing flexibility for renewables integration this can also the economic benefits to the low-voltage subsystems with each additional system connected. Comparison of a traditional single-level decision structure with the co-optimization approach illustrates a reduction in overall system cost under co-optimization, while specific cost allocations to transmission and distribution systems are changed.
Saturn launch vehicles airborne measuring and telemetry instrumentation systems design for reliable operation during short periods
Nutating stepping motor consists of an output rotating gear and a nutating gear. A flueric logic circuit controls the nutating motor. The complete system constitutes a reliable, open loop actuator system with inherently high output stiffness, reasonable slewing speeds and small step size.
Differential thermal expansion has been shown to be responsible for many observed failures in ceramic chip capacitors mounted on alumina substrates. The present work has shown that the mounting techniques used in bonding the capacitors have a marked effect upon the thermally induced mechanical stress and thus the failure rate. A mathematical analysis of a composite model of the capacitor-substrate system to predict the magnitude of thermally induced stresses have been conducted. It has been experimentally observed that the stresses in more compliant bonding systems such as soft lead/tin and indium solders are significantly lower than those in hard solder and epoxy systems. From the data obtained, several recommendations are made concerning the optimum bonding system for the achievement of maximum reliability.
Differential thermal expansion has been shown to be responsible for many observed failures in ceramic chip capacitors mounted on alumina substrates. The present work has shown that the mounting techniques used in bonding the capacitors have a marked effect upon the thermally induced mechanical stress and thus the failure rate. A mathematical analysis of a composite model of the capacitor-substrate system to predict the magnitude of thermally induced stresses has been conducted. It has been observed that the stresses in more compliant bonding systems such as soft lead/tin and indium solders are significantly lower than those in hard solder and epoxy systems. The marked dependence upon heating and cooling rate has proven to be a determining factor in the prediction of failure in both the indium and tin/lead solder systems. This study has shown that the harder or higher melting solders are less susceptible to thermal cycling effects but that they are more likely to fail during initial processing operations. Recommendations are made concerning the optimum bonding system for the achievement of maximum reliability.
In order to communicate reliably and to reduce the required transmitter power, NASA uses coded communication systems on most of their deep space satellites and probes (e.g. Pioneer, Voyager, Galileo, and the TDRSS network). These communication systems use binary convolutional codes. Better codes make the system more reliable and require less transmitter power. However, there are no good construction techniques for convolutional codes. Thus, to find good convolutional codes requires an exhaustive search over the ensemble of all possible codes. In this paper, an efficient convolutional code search algorithm was implemented on an IBM RS6000 Model 580. The combination of algorithm efficiency and computational power enabled us to find, for the first time, the optimal rate 1/2, memory 14, convolutional code.
Humans play an important role in the overall reliability of engineering systems. More often accidents and systems failure are traced to human errors. Therefore, in order to have meaningful system risk analysis, the reliability of the human element must be taken into consideration. Describing the human error process by mathematical models is a key to analyzing contributing factors. Therefore, the objective of this research effort is to establish stochastic models substantiated by sound theoretic foundation to address the occurrence of human errors in the processing of the space shuttle.