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At least 1,513 records · Page 84

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NASA NTRS2007

Reliability Considerations for Composite Overwrapped Pressure Vessels on Spacecraft

Composite Overwrapped Pressure Vessels (COPVs) are used to store gases under high pressure onboard spacecraft. These are used for a variety of purposes such as propelling liquid fuel etc, Kevlar, glass, Carbon and other more recent fibers have all been in use to overwrap the vessels. COPVs usually have a thin metallic liner with the primary purpose of containing the gases and prevent any leakage. The liner is overwrapped with filament wound composite such as Kevlar, Carbon or Glass fiber. Although the liner is required to perform in the leak before break mode making the failure a relatively benign mode, the overwrap can fail catastrophically under sustained load due to stress rupture. It is this failure mode that is of major concern as the stored energy of such vessels is often great enough ta cause loss of crew and vehicle. The present paper addresses some of the reliability concerns associated specifically with Kevlar Composite Overwrapped Pressure Vessels. The primary focus of the paper is on how reliability of COPV's are established for the purpose of deciding in general their flight worthiness and continued use. Analytical models based on existing design data will be presented showing how to achieve the required reliability metric to the end of a specific period of performance. Uncertainties in the design parameters and how they affect reliability and confidence intervals will be addressed as well. Some trade studies showing how reliability changes with time during a program period will be presented.

Murthy, Pappu L. N.↗

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 NTRS2014

Facility Systems, Ground Support Systems, and Ground Support Equipment General Design Requirements

This standard establishes requirements and guidance for design and fabrication of ground systems (GS) that includes: ground support equipment (GSE), ground support systems (GSS), and facility ground support systems (F GSS) to provide uniform methods and processes for design and development of robust, safe, reliable, maintainable, supportable, and cost-effective GS in support of space flight and institutional programs and projects.

Ground Support Equipment↗

NASA NTRS1992

ASRM case insulation design and development

This paper describes the achievements made on the Advanced Solid Rocket Motor (ASRM) case insulation design and development program. The ASRM case insulation system described herein protects the metal case and joints from direct radiation and hot gas impingement. Critical failure of solid rocket systems is often traceable to failure of the insulation design. The wide ranging accomplishments included the development of a nonasbestos insulation material for ASRM that replaced the existing Redesigned Solid Rocket Motor (RSRM) asbestos-filled nitrile butadiene rubber (NBR) along with a performance gain of 300 pounds, and improved reliability of all the insulation joint designs, i.e., segmented case joint, case-to-nozzle and case-to-igniter joint. The insulation process development program included the internal stripwinding process. This process advancement allowed Aerojet to match to exceed the capability of other propulsion companies.

Bell, Matthew S.↗

NASA NTRS1998

Investigation of Springback Associated with Composite Material Component Fabrication (MSFC Center Director's Discretionary Fund Final Report, Project 94-09)

The objective of this research project was to examine processing and design parameters in the fabrication of composite components to obtain a better understanding and attempt to minimize springback associated with composite materials. To accomplish this, both processing and design parameters were included in a Taguchi-designed experiment. Composite angled panels were fabricated, by hand layup techniques, and the fabricated panels were inspected for springback effects. This experiment yielded several significant results. The confirmation experiment validated the reproducibility of the factorial effects, error recognized, and experiment as reliable. The material used in the design of tooling needs to be a major consideration when fabricating composite components, as expected. The factors dealing with resin flow, however, raise several potentially serious material and design questions. These questions must be dealt with up front in order to minimize springback: viscosity of the resin, vacuum bagging of the part for cure, and the curing method selected. These factors directly affect design, material selection, and processing methods.

Benzie, M. A.↗

NASA NTRS2000

Advanced Guidance and Control Project for Reusable Launch Vehicles

The goals of this project are to significantly reduce the time and cost associated with guidance and control design for reusable launch vehicles, and to increase their safety and reliability. Success will lead to reduced cycle times during vehicle design and to reduced costs associated with flying to new orbits, with new payloads, and with modified vehicles. Success will also lead to more robustness to unforeseen circumstances in flight thereby enhancing safety and reducing risk. There are many guidance and control methods available that hold some promise for improvement in the desired areas. Investigators are developing a representative set of independent guidance and control methods for this project. These methods are being incorporated into a high-fidelity off is being conducted across a broad range of flight requirements. The guidance and control methods that perform the best will have demonstrated the desired qualities.

Hanson, John M.↗

NASA NTRS1999

Three-Dimensional Gear Crack Propagation Studied

Gears used in current helicopters and turboprops are designed for light weight, high margins of safety, and high reliability. However, unexpected gear failures may occur even with adequate tooth design. To design an extremely safe system, the designer must ask and address the question, "What happens when a failure occurs?" With gear-tooth bending fatigue, tooth or rim fractures may occur. A crack that propagates through a rim will be catastrophic, leading to disengagement of the rotor or propeller, loss of an aircraft, and possible fatalities. This failure mode should be avoided. A crack that propagates through a tooth may or may not be catastrophic, depending on the design and operating conditions. Also, early warning of this failure mode may be possible because of advances in modern diagnostic systems. One concept proposed to address bending fatigue fracture from a safety aspect is a splittooth gear design. The prime objective of this design would be to control crack propagation in a desired direction such that at least half of the tooth would remain operational should a bending failure occur. A study at the NASA Lewis Research Center analytically validated the crack-propagation failsafe characteristics of a split-tooth gear. It used a specially developed three-dimensional crack analysis program that was based on boundary element modeling and principles of linear elastic fracture mechanics. Crack shapes as well as the crack-propagation life were predicted on the basis of the calculated stress intensity factors, mixed-mode crack-propagation trajectory theories, and fatigue crack-growth theories. The preceding figures show the effect of the location of initial cracks on crack propagation. Initial cracks in the fillet of the teeth produced stress intensity factors of greater magnitude (and thus, greater crack growth rates) than those in the root or groove areas of the teeth. Crack growth was simulated in a case study to evaluate crack-propagation paths. Tooth fracture was predicted from the crackgrowth simulation for an initial crack in the tooth fillet region. This was the desired failure mode for an ultrasafe design. Lastly, tooth loads on the uncracked mesh of the split-tooth design were up to five times greater than those on the cracked mesh if equal deflections of the cracked and uncracked teeth were considered. This effect needs to be considered in the design of a split-tooth configuration. This work was done in-house at Lewis in support of the National Rotorcraft Technology Center project, Ultra-Safe Gear Design, with the Boeing Defense and Space Group. The crack-propagation package was developed by the Cornell Fracture Group at Cornell University. The reported results, which are the initial findings of Lewis gear-crackpropagation research for the Rotorcraft Base Program, will be further investigated to develop generalized gear design guidelines.

Lewicki, David G.↗

NASA NTRS1992

Advanced techniques in reliability model representation and solution

The current tendency of flight control system designs is towards increased integration of applications and increased distribution of computational elements. The reliability analysis of such systems is difficult because subsystem interactions are increasingly interdependent. Researchers at NASA Langley Research Center have been working for several years to extend the capability of Markov modeling techniques to address these problems. This effort has been focused in the areas of increased model abstraction and increased computational capability. The reliability model generator (RMG) is a software tool that uses as input a graphical object-oriented block diagram of the system. RMG uses a failure-effects algorithm to produce the reliability model from the graphical description. The ASSURE software tool is a parallel processing program that uses the semi-Markov unreliability range evaluator (SURE) solution technique and the abstract semi-Markov specification interface to the SURE tool (ASSIST) modeling language. A failure modes-effects simulation is used by ASSURE. These tools were used to analyze a significant portion of a complex flight control system. The successful combination of the power of graphical representation, automated model generation, and parallel computation leads to the conclusion that distributed fault-tolerant system architectures can now be analyzed.

Palumbo, Daniel L.↗

NASA NTRS1994

NASA/CARES dual-use ceramic technology spinoff applications

NASA has developed software that enables American industry to establish the reliability and life of ceramic structures in a wide variety of 21st Century applications. Designing ceramic components to survive at higher temperatures than the capability of most metals and in severe loading environments involves the disciplines of statistics and fracture mechanics. Successful application of advanced ceramics material properties and the use of a probabilistic brittle material design methodology. The NASA program, known as CARES (Ceramics Analysis and Reliability Evaluation of Structures), is a comprehensive general purpose design tool that predicts the probability of failure of a ceramic component as a function of its time in service. The latest version of this software, CARESALIFE, is coupled to several commercially available finite element analysis programs (ANSYS, MSC/NASTRAN, ABAQUS, COSMOS/N4, MARC), resulting in an advanced integrated design tool which is adapted to the computing environment of the user. The NASA-developed CARES software has been successfully used by industrial, government, and academic organizations to design and optimize ceramic components for many demanding applications. Industrial sectors impacted by this program include aerospace, automotive, electronic, medical, and energy applications. Dual-use applications include engine components, graphite and ceramic high temperature valves, TV picture tubes, ceramic bearings, electronic chips, glass building panels, infrared windows, radiant heater tubes, heat exchangers, and artificial hips, knee caps, and teeth.

Powers, Lynn M.↗

NASA NTRS1987

A prediction model of the depth-of-discharge effect on the cycle life of a storage cell

Cycle life requirements are very high for batteries used in aerospace applications in low Earth orbit. The data base required to establish confidence in a particular cell design is thus both extensive and expensive. Reliable accelerated cycle life testing and performance decay modeling represent attractive alternatives to real-time tests of cycle life. In light of certain long-term cycle life test results, this paper examines a very simple performance decay model developed earlier. Application of that model to available data demonstrates a rigid relationship between a battery's expected cycle life and the depth of discharge of cycling. Further, modeling analysis of the data suggests that a significantly improved cycle life can be obtained with advanced components, materials, and designs; and that cycle life can be reliably predicted from the results of accelerated testing.

Thaller, Lawrence H.↗

NASA NTRS1987

A prediction model of the depth-of-discharge effect on the cycle life of a storge cell

Cycle life requirements are very high for batteries used in aerospace applications in low earth orbit. The data base required to establish confidence in a particular cell design is thus both extensive and expensive. Reliable accelerated cycle life testing and performance decay modeling represent attractive alternatives to real-time tests of cycle life. In light of certain long-term cycle life test results, this paper examines a very simple performance decay model developed earlier. Application of that model to available data demonstrates a rigid relationship between a battery's expected cycle life and the depth of discharge of cycling. Further, modeling analysis of the data suggests that a significantly improved cycle life can be obtained with advanced components, materials, and designs; and that cycle life can be reliably predicted from the results of accelerated testing.

Thaller, Lawrence H.↗

NASA NTRSDate not supplied

Optimization, Design, and Demonstration of 1 kW Stirling Controller Using Capacitor-based Power Factor Correction

Free-piston Stirling convertors provide efficient, reliable thermal to electric power conversion, provided they are paired with a reliable controller. This paper outlines work underway on design concepts for kilowatt-class controllers. Using passive power factor correction (PFC) this design explores the possibility of reducing programmatic risk through system simplification. Efficiency is maximized through incorporating wide-bandgap gallium nitride (GaN) switches, and passive PFC volume is minimized through the use of polymer multi-layer capacitors. This work is aimed at exploring new approaches for future Stirling controllers.

Christopher Barth↗

NASA NTRS1975

HOME - An application of fault-tolerant techniques and system self-testing

Hard Over Monitoring Equipment (HOME) has been designed to complement and enhance the flight safety of a flight research helicopter. HOME is an independent, highly reliable, and fail-safe special purpose computer that monitors the flight control commands issued by the flight control computer of the helicopter. In particular, HOME detects the issuance of a hazardous hard-over command for any of the four flight control axes and transfers the control of the helicopter to the flight safety pilot. The design of HOME incorporates certain reliability and fail-safe enhancement design features, such as triple modular redundancy, majority logic voting, fail-safe dual circuits, independent status monitors, in-flight self-test, and a built-in preflight exerciser. The HOME design and operation is described with special emphasis on the reliability and fail-safe aspects of the design.

Holden, D. G.↗

NASA NTRS1972

Extending the life and recycle capability of earth storable propellant systems.

Rocket propulsion systems for reusable vehicles will be required to operate reliably for a large number of missions with a minimum of maintenance and a fast turnaround. For the space shuttle reaction control system to meet these requirements, current and prior related system failures were examined for their impact on reuse and, where warranted, component design and/or system configuration changes were defined for improving system service life. It was found necessary to change the pressurization component arrangement used on many single-use applications in order to eliminate a prevalent check valve failure mode and to incorporate redundant expulsion capability in propellant tank designs to achieve the necessary system reliability. Material flaws in pressurant and propellant tanks were noted to have a significant effect on tank cycle life. Finally, maintenance considerations dictated a modularized systems approach, allowing the system to be removed from the vehicle for service and repair at a remote site.

Schweickert, T. F.↗

NASA NTRS1989

A performance assessment of a byzantine resilient fault-tolerant computer

This report presents the results of a performance analysis of a quad-redundant Fault-Tolerant Processor (FTP). The FTP is a computing system specifically designed for applications where very high reliability is required. Examples of such applications are flight control systems, nuclear power systems, and spacecraft control systems. The FTP performance was analyzed in a hierarchical manner encompassing the hardware, the operating system, and the application. At the hardware level, the hardware organization and design was assessed in relation to system throughput and response. Analysis at the operating system level revealed that the scheduler took only 3.2 percent of each 40ms frame, while the redundancy management software took 10.4 percent. The application level performance was analyzed via a synthetic workload and a representative flight control model. The estimated throughput for this application was found to be 317.6 KIPS if not exercising the voter. Exercising the voter to ensure fault tolerance will diminish this number linearly as the number of votes is increased. This performance analysis method was proven effective by uncovering undesirable behavior and anomalies in the FTP system.

Young, Steven D.↗

NASA NTRS1973

Statistical determination of space shuttle component dynamic magnification factors

A method is presented of obtaining vibration design loads for components and brackets. Dynamic Magnification Factors from applicable Saturn/Apollo qualification, reliability, and vibroacoustic tests have been statistically formulated into design nomographs. These design nomographs have been developed for different component and bracket types, mounted on backup structure or rigidly mounted and excited by sinusoidal or random inputs. Typical nomographs are shown.

Lehner, F.↗

NASA NTRS1993

Advanced Solid Rocket Motor nozzle development status

This paper presents a status update of the design and development of an improved nozzle for the Advanced Solid Rocket Motor (ASRM). The ASRM nozzle incorporates advanced state-of-the-art design features and materials which contribute to enhanced safety, reliability, performance, and producibility for the space shuttle boosters. During 1992 the nozzle design progressed through a successful Preliminary Design Review (PDR). An improved ablative material development program also culminated in the selection of new standard and low density carbon cloth phenolic prepreg offering reduced variability and improved process attributes. A subscale motor test series to evaluate new materials and design features was also completed. An overview update of the matured design characteristics, supporting analysis, key development-program results and program status and plans is reported.

Kearney, W. J.↗

NASA NTRS2002

Probabilistic Fatigue: Computational Simulation

Fatigue is a primary consideration in the design of aerospace structures for long term durability and reliability. There are several types of fatigue that must be considered in the design. These include low cycle, high cycle, combined for different cyclic loading conditions - for example, mechanical, thermal, erosion, etc. The traditional approach to evaluate fatigue has been to conduct many tests in the various service-environment conditions that the component will be subjected to in a specific design. This approach is reasonable and robust for that specific design. However, it is time consuming, costly and needs to be repeated for designs in different operating conditions in general. Recent research has demonstrated that fatigue of structural components/structures can be evaluated by computational simulation based on a novel paradigm. Main features in this novel paradigm are progressive telescoping scale mechanics, progressive scale substructuring and progressive structural fracture, encompassed with probabilistic simulation. These generic features of this approach are to probabilistically telescope scale local material point damage all the way up to the structural component and to probabilistically scale decompose structural loads and boundary conditions all the way down to material point. Additional features include a multifactor interaction model that probabilistically describes material properties evolution, any changes due to various cyclic load and other mutually interacting effects. The objective of the proposed paper is to describe this novel paradigm of computational simulation and present typical fatigue results for structural components. Additionally, advantages, versatility and inclusiveness of computational simulation versus testing are discussed. Guidelines for complementing simulated results with strategic testing are outlined. Typical results are shown for computational simulation of fatigue in metallic composite structures to demonstrate the versatility of this novel paradigm in predicting a priori fatigue life.

Chamis, Christos C.↗