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2002 Controls Design Challenge

This document is intended to provide the specifications and requirements for a flight control system design challenge. The response to the challenge will involve documenting whether the particular design has met the stated requirements through analysis and computer simulation. The response should be written in the general format of a technical publication with corresponding length limits, e.g., an approximate maximum length of 45 units, with each full-size figure and double-spaced typewritten page constituting one unit.

Hess, Ronald A.↗

Vibration Based Crack Detection in a Rotating Disk: An Analytical Study - Part 1

This paper describes the analytical results concerning the detection of a crack in a rotating disk. The concept of the approach is based on the fact that the development of a disk crack results in a distorted strain field within the component. As a result, a minute deformation in the disk's geometry as well as a change in the system s center of mass occurs. Finite element analyses were conducted concerning a notched disk in order to define the sensitivity of the method. The notch was used to simulate an actual crack and will be the method utilized for upcoming experiments. Various notch sizes were studied. The geometric deformations and shifts of center of mass were documented as a function of rotational speed. In addition, a rotordynamic analysis of a 2-bearing, disk and shaft system was conducted. The overall response of the system was required in order to design the experimental system for operation beyond the first critical. The results of the FE analyses of the disk indicated that the overall changes in the disk s geometry and center of mass were rather small. The difference between the maximum centrifugal radial displacements between the undamaged and damaged disks at 8000 RPM was 0.00014 in. for a 0.963 in. notch length. The shift in center of mass was also of this magnitude. The next step involves running experiments to verify the analysis.

Gyekenyesi, Andrew L.↗

Multi-Discipline Analytical Modeling of a Cracked Disk in a Turbine Engine: Applied to TF41 Experiment at China Lake

The investigated crack detection method is based on the fact that the development of a disk crack results in a distorted strain field within the component. As a result, a minute deformation in the disk's geometry as well as a change in the system's center of mass occurs. Finite element analyses were conducted concerning a notched disk in order to define the sensitivity of the method. The notch was used to simulate an actual crack and will be the method utilized for upcoming experiments. Various notch sizes were studied and the geometric deformations and shifts of center of mass were documented as a function of rotational speed. In addition, a rotordynamic analysis of a two-bearing, disk and shaft system was conducted. The results of the FE analyses of the disk indicated that the overall changes in the disk's geometry and center of mass were rather small. Comparing the 9.25 in. disk's maximum radial displacements due centrifugal forces at 8000 RPM between an un-notched and a 0.962 in. notched disk, the difference was on the order of 0.00014 in. The shift in center of mass was also of this magnitude. The next step involves running experiments to verify the analysis.

Sawicki, Jerzy T.↗

A Large-Scale Design Integration Approach Developed in Conjunction with the Ares Launch Vehicle Program

This paper presents a method for performing large-scale design integration, taking a classical 2D drawing envelope and interface approach and applying it to modern three dimensional computer aided design (3D CAD) systems. Today, the paradigm often used when performing design integration with 3D models involves a digital mockup of an overall vehicle, in the form of a massive, fully detailed, CAD assembly; therefore, adding unnecessary burden and overhead to design and product data management processes. While fully detailed data may yield a broad depth of design detail, pertinent integration features are often obscured under the excessive amounts of information, making them difficult to discern. In contrast, the envelope and interface method results in a reduction in both the amount and complexity of information necessary for design integration while yielding significant savings in time and effort when applied to today's complex design integration projects. This approach, combining classical and modern methods, proved advantageous during the complex design integration activities of the Ares I vehicle. Downstream processes, benefiting from this approach by reducing development and design cycle time, include: Creation of analysis models for the Aerodynamic discipline; Vehicle to ground interface development; Documentation development for the vehicle assembly.

Redmon, John W.↗

Towards Understanding the DO-178C / ED-12C Assurance Case

This paper describes initial work towards building an explicit assurance case for DO-178C / ED-12C. Two specific questions are explored: (1) What are some of the assumptions upon which the guidance in the document relies, and (2) What claims are made concerning test coverage analysis?

Holloway, C M.↗

Integrating Condition Indicators and Usage Parameters for Improved Spiral Bevel Gear Health Monitoring

The objective of this study was to illustrate the importance of combining Health Usage Monitoring Systems (HUMS) data with usage monitoring system data when detecting rotorcraft transmission health. Six gear sets were tested in the NASA Glenn Spiral Bevel Gear Fatigue Rig. Damage was initiated and progressed on the gear and pinion teeth. Damage progression was measured by debris generation and documented with inspection photos at varying torque values. A contact fatigue analysis was applied to the gear design indicating the effect temperature, load and reliability had on gear life. Results of this study illustrated the benefits of combining HUMS data and actual usage data to indicate progression of damage for spiral bevel gears.

Dempsey, Paula J.↗

Integrating Condition Indicators and Usage Parameters for Improved Spiral Bevel Gear Health Monitoring

The objective of this study was to illustrate the importance of combining Health Usage Monitoring Systems (HUMS) data with usage monitoring system data when detecting rotorcraft transmission health. Three gear sets were tested in the NASA Glenn Spiral Bevel Gear Fatigue Rig. Damage was initiated and progressed on the gear and pinion teeth. Damage progression was measured by debris generation and documented with inspection photos at varying torque values. A contact fatigue analysis was applied to the gear design indicating the effect temperature, load and reliability had on gear life. Results of this study illustrated the benefits of combining HUMS data and actual usage data to indicate progression of damage for spiral bevel gears.

Dempsey, Paula J.↗

Experiences with Extra-Vehicular Activities in Response to Critical ISS Contingencies

The maturation of the International Space Station (ISS) design from the proposed Space Station Freedom to today's current implementation resulted in external hardware redundancy vulnerabilities in the final design. Failure to compensate for or respond to these vulnerabilities could put the ISS in a posture to where it could no longer function as a habitable space station. In the first years of ISS assembly, these responses were to largely be addressed by the continued resupply and Extra-Vehicular Activity (EVA) capabilities of the Space Shuttle. Even prior to the decision to retire the Space Shuttle, it was realized that ISS needed to have its own capability to be able to rapidly repair or replace external hardware without needing to wait for the next cargo resupply mission. As documented in a previous publicatoin5, in 2006 development was started to baseline Extra- Vehicular Activity (EVA, or spacewalk) procedures to replace hardware components whose failure would expose some of the ISS vulnerabilities should a second failure occur. This development work laid the groundwork for the onboard crews and the ground operations and engineering teams to be ready to replace any of this failed hardware. In 2010, this development work was put to the test when one of these pieces of hardware failed. This paper will provide a brief summary of the planning and processes established in the original Contingency EVA development phase. It will then review how those plans and processes were implemented in 2010, highlighting what went well as well as where there were deficiencies between theory and reality. This paper will show that the original approach and analyses, though sound, were not as thorough as they should have been in the realm of planning for next worse failures, for documenting Programmatic approval of key assumptions, and not pursuing sufficient engineering analysis prior to the failure of the hardware. The paper will further highlight the changes made to the Contingency EVA preparation team structure, approach, goals, and the resources allocated to its work after the 2010 events. Finally, the authors will overview the implementation of these updates in addressing failures onboard the ISS in 2012, 2013, and 2014. The successful use of the updated approaches, and the application of the approaches to other spacewalks, will demonstrate the effectiveness of this additional work and make a case for putting significant time and resources into pre-failure planning and analysis for critical hardware items on human-tended spacecraft.

Van Cise, E. A.↗

Experiences with Extra-Vehicular Activities in Response to Critical ISS Contingencies

The maturation of the International Space Station (ISS) design from the proposed Space Station Freedom to today's current implementation resulted in external hardware redundancy vulnerabilities in the final design. Failure to compensate for or respond to these vulnerabilities could put the ISS in a posture where it could no longer function as a habitable space station. In the first years of ISS assembly, these responses were to largely be addressed by the continued resupply and Extra-Vehicular Activity (EVA) capabilities of the Space Shuttle. Even prior to the decision to retire the Space Shuttle, it was realized that ISS needed to have its own capability to be able to rapidly repair or replace external hardware without needing to wait for the next cargo resupply mission. As documented in a previous publication, in 2006 development was started to baseline Extra-Vehicular Activity (EVA, or spacewalk) procedures to replace hardware components whose failure would expose some of the ISS vulnerabilities should a second failure occur. This development work laid the groundwork for the onboard crews and the ground operations and engineering teams to be ready to replace any of this failed hardware. In 2010, this development work was put to the test when one of these pieces of hardware failed. This paper will provide a brief summary of the planning and processes established in the original Contingency EVA development phase. It will then review how those plans and processes were implemented in 2010, highlighting what went well as well as where there were deficiencies between theory and reality. This paper will show that the original approach and analyses, though sound, were not as thorough as they should have been in the realm of planning for next worse failures, for documenting Programmatic approval of key assumptions, and not pursuing sufficient engineering analysis prior to the failure of the hardware. The paper will further highlight the changes made to the Contingency EVA preparation team structure, approach, goals, and the resources allocated to its work after the 2010 events. Finally, the authors will overview the implementation of these updates in addressing failures onboard the ISS in 2012, 2013, and 2014. The successful use of the updated approaches, and the application of the approaches to other spacewalks, will demonstrate the effectiveness of this additional work and make a case for putting significant time and resources into pre-failure planning and analysis for critical hardware items on human-tended spacecraft.

Van Cise, E. A.↗

Electrical, Electronic, and Electromechanical (EEE) Parts Management and Control Requirements for Space Flight Hardware and Critical Ground Support Equipment...aka... The NASA EEE Parts Standard, NASA-STD 8739.10

Describes development and content of a new NASA Standard for Electrical Electronic and Electromechanical (EEE) parts. This Standard reflects current practices, instead of changing them. Most NASA Centers utilize local documents, but there is minimal consistency across the Agency. A gap analysis clearly shows the differences that exist among the different centers and with respect to the NASA Parts Policy. Once approved, the new standard can be referenced in contracts and agreements with organizations outside of NASA.

Electronic↗

NASA Fastener Procurement, Receiving Inspection, and Storage Practices for NASA Mission Hardware

This document establishes minimum requirements for supply chain risk management, procurement, receiving inspection, testing, traceability management, and storage practices for fasteners used in NASA mission hardware. This document does not contain fastener requirements pertaining to design or design analysis; design and design analysis requirements are contained in NASA-STD-5020, Requirements for Threaded Fastening Systems in Spaceflight Hardware.

Safety and Mission Assurance↗

Fostering Open Science Inclusiveness for Interdisciplinary Users of Earth Observations

The term Open Science is subject to a variety of interpretations because of a key (and useful) ambiguity in the meaning of “Open”. Open in the sense of Transparency enables more trust in science research by making the details of the scientific process visible and accessible to anyone. “Open” in the sense of Inclusiveness enables more scientists from other disciplines to participate in research in a given discipline, thus producing more interdisciplinary research. Data Systems can play a major role in enabling Open (Inclusive) Science by making it easier for users from other disciplines to work with data within a given discipline. This is challenging for Earth Observation datasets, most of which are the product of advanced instrumentation and sophisticated, specialized variable retrieval algorithms and code. Serving the “extra-disciplinary”communities begins with simple things, like accessible, readable data documentation with adequate scaffolding. But just as important is provisioning Analysis-Ready data that does not require expert pre-processing. Disciplines also often have dominant toolsets, such as R in the biomass community or GIS in many applications communities. Ensuring that EO data are easy to use in the tools favored in other communities will enable more interdisciplinary research. Ideally, interdisciplinary research also benefits from scientists with different domain expertise. Platforms and frameworks that facilitate frictionless collaboration with discipline experts, together with capacity building efforts in those external disciplines also improve the inclusiveness aspect of Open Science. In short, Open Science is at root a way of thinking about how users from diverse discipline can best access and use data and services from a particular discipline.

Christopher Lynnes↗

Managing Maintenance Error: Six Lessons From Aviation Maintenance

There are clear parallels between the ground processing of spacecraft and the maintenance of airline aircraft. In both cases, reliable human performance is critical to safe outcomes. Examples of human factors in airline maintenance and spacecraft ground processing illustrate the similarities between these two domains. The worldwide aviation industry began to pay close attention to human factors in maintenance after several maintenance-related disasters in the 1970s and 80s. Rather than simply applying solutions that had been developed for flight crew and air traffic controllers, the aviation industry developed human factors interventions specifically tailored for maintenance personnel. These interventions have led to safety improvements, greater reliability, and significant cost savings. Six human factors approaches from airline maintenance that can be usefully applied to enhance the quality and safety of ground processing are outlined. These are 1) Design for assembly, test, and maintenance, 2) Non technical skills training, 3) Improved design of documentation, 4) Reduction of iatrogenic quality lapses, 5) Barrier and control analysis, and 6) Continuous improvement based on learning from quality lapses.

maintenance human factors↗

A Frank Discussion on Lessons Learned From Adopting and Applying NASA-STD-6030 for Spaceflight Systems

With the advancement and adoption of Additive Manufacturing (AM) for spaceflight systems, numerous lessons have been learned during the qualification and certification of AM components. The lessons learned covered in this presentation will provide an overview of the challenges faced by NASA centers and commercial partners working to design AM hardware that complies with NASA-STD-6030 Additive Manufacturing Requirements (AMR). Topics of interest include tailoring of requirements for specific projects, documentation requirements, and addressing conservative approaches towards mechanical property development and analysis. In addition to that, this presentation aims to impress that these lessons learned will influence the future revisions of the NASA technical standard to facilitate and advance AM technology adoption on NASA projects.

Additive Manufacturing↗

Summary of INL Integrated Energy Systems Research for the Global National Laboratories Consortium on IES

The DOE Office of Nuclear Energy (DOE-NE) program on Integrated Energy Systems (IES) is led by researchers at Idaho National Laboratory (INL), and work is conducted in partnership with an array of other DOE laboratories, industry, and academia. IES research and development activities are additionally complimented by the DOE-NE Light Water Reactor Sustainability (LWRS) program, where work under the Flexible Plant Operations & Generation pathway supports analysis of opportunities for non-electric applications of current fleet nuclear plants and collaborates with multiple plants on near-term hydrogen production demonstration opportunities. The DOE-NE programs additionally partner with the Hydrogen and Fuel Cell Technologies Office under the DOE Office of Energy Efficiency and Renewable Energy to jointly fund the development of analysis tools, technologies, and nuclear-integrated hydrogen demonstration projects. This document provides a brief, high-level summary of IES work as contribution to the annual report for the Global National Laboratories Consortium on IES.

08 HYDROGEN↗

Computational Analysis of Hydraulic Efficiency of Michigan DOT Covers J and K

Drainage structures are used in urban street and highway systems to capture stormwater runoff. These structures typically consist of catch basins fitted with grates, inlets, or combination grate/inlet configurations that collect runoff and convey it through buried drainage systems. They are strategically placed within curb-and-gutter systems to enhance public safety by efficiently removing water from roadways and thereby reducing the risk of hydroplaning. The performance of drainage structures is commonly evaluated in terms of hydraulic efficiency, defined as the percentage of flow captured by the basin relative to the total flow reaching the structure. Understanding the hydraulic performance of these structures allows designers to properly space inlets, resulting in cost-effective designs that also help ensure the safety of the traveling public. MDOT uses a variety of drainage structures for runoff capture, as documented in Michigan Department of Transportation (MDOT) Drainage Manual. Many of these structures incorporate sinusoidal-type grates that are not addressed in HEC-22. Because physical modeling of these structures has been limited, further analysis is needed to verify their capture efficiency. Under current MDOT practice, the capture efficiency of these grates is estimated by assuming performance similar to that of a comparably sized reticuline grate described in HEC22. The first phase of this effort, titled Computational Analysis of Hydraulic Efficiency of Michigan DOT Cover C, focused on evaluating the hydraulic performance of MDOT’s Cover C grate. Cover C was selected as the initial test candidate because its sinusoidal pattern is representative of other MDOT grates, while it is typically used in high-volume, higher-speed applications. A similar version, Cover CX, is used on interstate highways but does not include transverse bars for bicycle safety. The current second phase of the study expands this work to evaluate MDOT’s Covers J and K. These grates were selected for additional analysis to further assess the hydraulic performance of MDOT drainage structures that are not directly represented by grate configurations in HEC-22. The results of this phase will build on the findings from the Cover C analysis and support improved understanding of the capture efficiency of MDOT’s standard drainage grates. This report is intended to serve as a companion document to the earlier study, Computational Analysis of Hydraulic Efficiency of Michigan DOT Cover C [3]. The present work applies the same overall CFD-based evaluation approach to MDOT Covers J and K and compares the resulting performance trends with those previously identified for Cover C. In particular, both studies assess on-grade interception efficiency, sag-location hydraulic capacity, and the effects of partial obstruction relative to HEC-22-based design estimates.

42 ENGINEERING↗

Enhancing Developer Productivity - L2 Milestone (Final Report)

This report documents the work done as part of the “Enhancing Developer Productivity” level 2 milestone. The team surveyed developers about impediments and successes; improved our CI pipeline monitoring and reporting; developed tools for line coverage reporting and analysis; improved compiler warning adherence in SIERRA; prototyped static analysis, AI, and mutation testing tooling in SIERRA; and developed a 3-5 year SIERRA plan document to help these initiatives continue past this milestone.

97 MATHEMATICS AND COMPUTING↗

Complete Decoding and Reporting of Aviation Routine Weather Reports (METARs)

Aviation Routine Weather Report (METAR) provides surface weather information at and around observation stations, including airport terminals. These weather observations are used by pilots for flight planning and by air traffic service providers for managing departure and arrival flights. The METARs are also an important source of weather data for Air Traffic Management (ATM) analysts and researchers at NASA and elsewhere. These researchers use METAR to correlate severe weather events with local or national air traffic actions that restrict air traffic, as one example. A METAR is made up of multiple groups of coded text, each with a specific standard coding format. These groups of coded text are located in two sections of a report: Body and Remarks. The coded text groups in a U.S. METAR are intended to follow the coding standards set by National Oceanic and Atmospheric Administration (NOAA). However, manual data entry and edits made by a human report observer may result in coded text elements that do not follow the standards, especially in the Remarks section. And contrary to the standards, some significant weather observations are noted only in the Remarks section and not in the Body section of the reports. While human readers can infer the intended meaning of non-standard coding of weather conditions, doing so with a computer program is far more challenging. However such programmatic pre-processing is necessary to enable efficient and faster database query when researchers need to perform any significant historical weather analysis. Therefore, to support such analysis, a computer algorithm was developed to identify groups of coded text anywhere in a report and to perform subsequent decoding in software. The algorithm considers common deviations from the standards and data entry mistakes made by observers. The implemented software code was tested to decode 12 million reports and the decoding process was able to completely interpret 99.93 of the reports. This document presents the deviations from the standards and the decoding algorithm. Storing all decoded data in a database allows users to quickly query a large amount of data and to perform data mining on the data. Users can specify complex query criteria not only on date or airport but also on weather condition. This document also describes the design of a database schema for storing the decoded data, and a Data Warehouse web application that allows users to perform reporting and analysis on the decoded data. Finally, this document presents a case study correlating dust storms reported in METARs from the Phoenix International airport with Ground Stops issued by Air Route Traffic Control Centers (ATCSCC). Blowing widespread dust is one of the weather conditions when dust storm occurs. By querying the database, 294 METARs were found to report blowing widespread dust at the Phoenix airport and 41 of them reported such condition only in the Remarks section of the reports. When METAR is a data source for an ATM research, it is important to include weather conditions not only from the Body section but also from the Remarks section of METARs.

METAR Decoder/Parser↗