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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.

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NASA NTRS2003

Data-Mining Toolset Developed for Determining Turbine Engine Part Life Consumption

The current practice in aerospace turbine engine maintenance is to remove components defined as life-limited parts after a fixed time, on the basis of a predetermined number of flight cycles. Under this schedule-based maintenance practice, the worst-case usage scenario is used to determine the usable life of the component. As shown, this practice often requires removing a part before its useful life is fully consumed, thus leading to higher maintenance cost. To address this issue, the NASA Glenn Research Center, in a collaborative effort with Pratt & Whitney, has developed a generic modular toolset that uses data-mining technology to parameterize life usage models for maintenance purposes. The toolset enables a "condition-based" maintenance approach, where parts are removed on the basis of the cumulative history of the severity of operation they have experienced. The toolset uses data-mining technology to tune life-consumption models on the basis of operating and maintenance histories. The flight operating conditions, represented by measured variables within the engine, are correlated with repair records for the engines, generating a relationship between the operating condition of the part and its service life. As shown, with the condition-based maintenance approach, the lifelimited part is in service until its usable life is fully consumed. This approach will lower maintenance costs while maintaining the safety of the propulsion system. The toolset is a modular program that is easily customizable by users. First, appropriate parametric damage accumulation models, which will be functions of engine variables, must be defined. The tool then optimizes the models to match the historical data by computing an effective-cycle metric that reduces the unexplained variability in component life due to each damage mode by accounting for the variability in operational severity. The damage increment due to operating conditions experienced during each flight is used to compute the effective cycles and ultimately the replacement time. Utilities to handle data problems, such as gaps in the flight data records, are included in the toolset. The tool was demonstrated using the first stage, high-pressure turbine blade of the PW4077 engine (Pratt & Whitney, East Hartford, CT). The damage modes considered were thermomechanical fatigue and oxidation/erosion. Each PW4077 engine contains 82 first-stage, high-pressure turbine blades, and data from a fleet of engines were used to tune the life-consumption models. The models took into account not only measured variables within the engine, but also unmeasured variables such as engine health parameters that are affected by degradation of the engine due to aging. The tool proved effective at predicting the average number of blades scrapped over time due to each damage mode, per engine, given the operating history of the engine. The customizable tools are available to interested parties within the aerospace community.

Litt, Jonathan S.↗

NASA NTRS1997

On-Line Modal State Monitoring of Slowly Time-Varying Structures

Monitoring the dynamic response of structures is often performed for a variety of reasons. These reasons include condition-based maintenance, health monitoring, performance improvements, and control. In many cases the data analysis that is performed is part of a repetitive decision-making process, and in these cases the development of effective on-line monitoring schemes help to speed the decision-making process and reduce the risk of erroneous decisions. This report investigates the use of spatial modal filters for tracking the dynamics of slowly time-varying linear structures. The report includes an overview of modal filter theory followed by an overview of several structural system identification methods. Included in this discussion and comparison are H-infinity, eigensystem realization, and several time-domain least squares approaches. Finally, a two-stage adaptive on-line monitoring scheme is developed and evaluated.

Johnson, Erik A.↗

NASA NTRS2005

Intelligent, Self-Diagnostic Thermal Protection System for Future Spacecraft

The goal of this project is to provide self-diagnostic capabilities to the thermal protection systems (TPS) of future spacecraft. Self-diagnosis is especially important in thermal protection systems (TPS), where large numbers of parts must survive extreme conditions after weeks or years in space. In-service inspections of these systems are difficult or impossible, yet their reliability must be ensured before atmospheric entry. In fact, TPS represents the greatest risk factor after propulsion for any transatmospheric mission. The concepts and much of the technology would be applicable not only to the Crew Exploration Vehicle (CEV), but also to ablative thermal protection for aerocapture and planetary exploration. Monitoring a thermal protection system on a Shuttle-sized vehicle is a daunting task: there are more than 26,000 components whose integrity must be verified with very low rates of both missed faults and false positives. The large number of monitored components precludes conventional approaches based on centralized data collection over separate wires; a distributed approach is necessary to limit the power, mass, and volume of the health monitoring system. Distributed intelligence with self-diagnosis further improves capability, scalability, robustness, and reliability of the monitoring subsystem. A distributed system of intelligent sensors can provide an assurance of the integrity of the system, diagnosis of faults, and condition-based maintenance, all with provable bounds on errors.

Hyers, Robert W.↗

NASA NTRS2006

Microwave Blade Tip Clearance System: An Update

Newer engines use compressor bleed air and a model to close clearances open loop. Measuring clearances and closing the control loop can add additional efficiencies. Tip clearance control has been identified as a key technology for future engines Additional benefits in prognostics, NSMS, and condition-based maintenance. In the HPT for every 1 mil improvement in clearance: a) SFC decreases 0.1%; and b) EGT margin increases 1 C.

Geisheimer, Jon↗

NASA NTRS2006

NASA Stennis Space Center Integrated System Health Management Test Bed and Development Capabilities

Integrated System Health Management (ISHM) is a capability that focuses on determining the condition (health) of every element in a complex System (detect anomalies, diagnose causes, prognosis of future anomalies), and provide data, information, and knowledge (DIaK)-not just data-to control systems for safe and effective operation. This capability is currently done by large teams of people, primarily from ground, but needs to be embedded on-board systems to a higher degree to enable NASA's new Exploration Mission (long term travel and stay in space), while increasing safety and decreasing life cycle costs of spacecraft (vehicles; platforms; bases or outposts; and ground test, launch, and processing operations). The topics related to this capability include: 1) ISHM Related News Articles; 2) ISHM Vision For Exploration; 3) Layers Representing How ISHM is Currently Performed; 4) ISHM Testbeds & Prototypes at NASA SSC; 5) ISHM Functional Capability Level (FCL); 6) ISHM Functional Capability Level (FCL) and Technology Readiness Level (TRL); 7) Core Elements: Capabilities Needed; 8) Core Elements; 9) Open Systems Architecture for Condition-Based Maintenance (OSA-CBM); 10) Core Elements: Architecture, taxonomy, and ontology (ATO) for DIaK management; 11) Core Elements: ATO for DIaK Management; 12) ISHM Architecture Physical Implementation; 13) Core Elements: Standards; 14) Systematic Implementation; 15) Sketch of Work Phasing; 16) Interrelationship Between Traditional Avionics Systems, Time Critical ISHM and Advanced ISHM; 17) Testbeds and On-Board ISHM; 18) Testbed Requirements: RETS AND ISS; 19) Sustainable Development and Validation Process; 20) Development of on-board ISHM; 21) Taxonomy/Ontology of Object Oriented Implementation; 22) ISHM Capability on the E1 Test Stand Hydraulic System; 23) Define Relationships to Embed Intelligence; 24) Intelligent Elements Physical and Virtual; 25) ISHM Testbeds and Prototypes at SSC Current Implementations; 26) Trailer-Mounted RETS; 27) Modeling and Simulation; 28) Summary ISHM Testbed Environments; 29) Data Mining - ARC; 30) Transitioning ISHM to Support NASA Missions; 31) Feature Detection Routines; 32) Sample Features Detected in SSC Test Stand Data; and 33) Health Assessment Database (DIaK Repository).

Figueroa, Fernando↗

NASA NTRS2010

Monitoring System for Storm Readiness and Recovery of Test Facilities: Integrated System Health Management (ISHM) Approach

Severe weather events are likely occurrences on the Mississippi Gulf Coast. It is important to rapidly diagnose and mitigate the effects of storms on Stennis Space Center's rocket engine test complex to avoid delays to critical test article programs, reduce costs, and maintain safety. An Integrated Systems Health Management (ISHM) approach and technologies are employed to integrate environmental (weather) monitoring, structural modeling, and the suite of available facility instrumentation to provide information for readiness before storms, rapid initial damage assessment to guide mitigation planning, and then support on-going assurance as repairs are effected and finally support recertification. The system is denominated Katrina Storm Monitoring System (KStorMS). Integrated Systems Health Management (ISHM) describes a comprehensive set of capabilities that provide insight into the behavior the health of a system. Knowing the status of a system allows decision makers to effectively plan and execute their mission. For example, early insight into component degradation and impending failures provides more time to develop work around strategies and more effectively plan for maintenance. Failures of system elements generally occur over time. Information extracted from sensor data, combined with system-wide knowledge bases and methods for information extraction and fusion, inference, and decision making, can be used to detect incipient failures. If failures do occur, it is critical to detect and isolate them, and suggest an appropriate course of action. ISHM enables determining the condition (health) of every element in a complex system-of-systems or SoS (detect anomalies, diagnose causes, predict future anomalies), and provide data, information, and knowledge (DIaK) to control systems for safe and effective operation. ISHM capability is achieved by using a wide range of technologies that enable anomaly detection, diagnostics, prognostics, and advise for control: (1) anomaly detection algorithms and strategies, (2) fusion of DIaK for anomaly detection (model-based, numerical, statistical, empirical, expert-based, qualitative, etc.), (3) diagnostics/prognostics strategies and methods, (4) user interface, (5) advanced control strategies, (6) integration architectures/frameworks, (7) embedding of intelligence. Many of these technologies are mature, and they are being used in the KStorMS. The paper will describe the design, implementation, and operation of the KStorMS; and discuss further evolution to support other needs such as condition-based maintenance (CBM).

Figueroa, Fernando↗

NASA NTRS2013

Model-Based Diagnosis and Prognosis of a Water Recycling System

A water recycling system (WRS) deployed at NASA Ames Research Center s Sustainability Base (an energy efficient office building that integrates some novel technologies developed for space applications) will serve as a testbed for long duration testing of next generation spacecraft water recycling systems for future human spaceflight missions. This system cleans graywater (waste water collected from sinks and showers) and recycles it into clean water. Like all engineered systems, the WRS is prone to standard degradation due to regular use, as well as other faults. Diagnostic and prognostic applications will be deployed on the WRS to ensure its safe, efficient, and correct operation. The diagnostic and prognostic results can be used to enable condition-based maintenance to avoid unplanned outages, and perhaps extend the useful life of the WRS. Diagnosis involves detecting when a fault occurs, isolating the root cause of the fault, and identifying the extent of damage. Prognosis involves predicting when the system will reach its end of life irrespective of whether an abnormal condition is present or not. In this paper, first, we develop a physics model of both nominal and faulty system behavior of the WRS. Then, we apply an integrated model-based diagnosis and prognosis framework to the simulation model of the WRS for several different fault scenarios to detect, isolate, and identify faults, and predict the end of life in each fault scenario, and present the experimental results.

Roychoudhury, Indranil↗

NASA NTRS2013

Continued Evaluation of Gear Condition Indicator Performance on Rotorcraft Fleet

This paper details analyses of condition indicator performance for the helicopter nose gearbox within the U.S. Army's Condition-Based Maintenance Program. Ten nose gearbox data sets underwent two specific analyses. A mean condition indicator level analysis was performed where condition indicator performance was based on a 'batting average' measured before and after part replacement. Two specific condition indicators, Diagnostic Algorithm 1 and Sideband Index, were found to perform well for the data sets studied. A condition indicator versus gear wear analysis was also performed, where gear wear photographs and descriptions from Army tear-down analyses were categorized based on ANSI/AGMA 1010-E95 standards. Seven nose gearbox data sets were analyzed and correlated with condition indicators Diagnostic Algorithm 1 and Sideband Index. Both were found to be most responsive to gear wear cases of micropitting and spalling. Input pinion nose gear box condition indicators were found to be more responsive to part replacement during overhaul than their corresponding output gear nose gear box condition indicators.

Delgado, Irebert R.↗

NASA NTRS2018

A Prognostics Framework Development for Swarm Satellite Formations

Prognostics is the science of predicting the failure(s) of a component or a system and understanding how the performance will change in the event of a failure or degradation mechanism. With accurate predictions of possible failures, autonomous mitigative actions can be taken to correct/repair any issues or alert human operators of a failure threshold exceedance requiring condition-based maintenance. Although there is extensive research on failure predictions for a component or a system, there are significantly more opportunities to foray into failure predictions and prognostics for a system of systems such as an airspace consisting of multiple aircraft, a fleet of unmanned aerial vehicles, and a swarm of intelligent satellite systems. Failure prediction and mitigation are particularly important in autonomous systems such as satellite swarm systems that need effective resource management and minimal human interactions. Based on NASA's decadal survey, there is a clear need to prioritize the development of satellite swarm technology for studies of space physics and Earth science. The science community will propose future missions that return in-situ measurements from a 3-D (three-dimensional) volume of space, with relative spacecraft motion and inter-satellite baselines controlled according to the mission objectives. For such multi-spacecraft missions, it is required that ground operations resources do not scale with the number of satellites, thus compromising the swarm or leading to inefficiencies in resource allocation. Swarms of tens or hundreds of small satellites will require autonomy in attitude control, navigation and failure. Although significant research has been conducted in the areas of autonomous formation flying algorithms, less attention has been given to the development of resilient systems robust to failures.The focus of this research paper is the integration of model-based prognostics into the swarm dynamics control and decision-making algorithms. We simulate swarm management strategies for a subsystem failure to demonstrate the importance of failure predictions by comparing two cases: (i) no health information is provided to the system and utilized in the decision-making process and (2) system health information is obtained using prognostics and employed by the control system. One example scenario presented is for the GPS (Global Positioning System) system of an individual satellite to perform off-nominally due to increasing estimated error. In this scenario, the keep-out zone for that satellite would become more conservative, thereby decreasing the risk of collision. This is achieved via tuning the individual artificial repulsive functions assigned to each satellite.This paper is structured as follows. First we provide an overview of current swarm technology development, where we specifically use the term swarm to define multiple satellites flying in formation in similar orbits, with cross-link communication and station-keeping capabilities. Second, we give an introduction to the Swarm Orbital Dynamics Advisor (SODA), a tool that accepts high-level configuration commands and provides the orbital maneuvers required to achieve the prescribed formation configuration. Third, we provide the details of the model-based prognostics algorithm implementation in SODA. Finally, we present different case studies for potential component/subsystem failures and the swarm responses based with and without failure prediction information.

prognostics↗

NASA NTRS2018

Dynamic Adjustment of Simulation Parameters for Efficient Vehicle Prognostics

Model-based diagnostics and prognostics rely on state estimation and uncertainty management algorithms to produce useful information for system operators and maintainers. This information enables more informed operational decisions, condition-based maintenance, and overall mission safety assurance. Typically, uncertainty is associated with vehicle state-of-health estimation and prediction results because of modeling errors, internal or external sources of noise, and sensor inaccuracy. Probabilistic uncertainty management methods including Sequential Monte Carlo simulation are commonly used to reason about state-of-health estimates and predictions in the presence of these sources of uncertainty. However, such algorithms can be computationally expensive as they require a very large number of samples to obtain a sufficiently accurate quantification of the end of life probability distribution. As a result, highly mobile autonomous systems that leverage the prognostic results for mission-level replanning are often constrained in their processing capability because of these computationally expensive simulation approaches. Therefore, in this paper, we investigate algorithmic methods for dynamically adjusting simulation time step as well as number of samples to achieve highly efficient prognostic results while maintaining results accuracy. Results obtained from simulated flight experiments of an electric unmanned aerial vehicle are presented to verify the efficacy of such algorithms.

Prognostics↗

NASA NTRSDate not supplied

Physics-Guided Deep Learning for Complex System Health Management and Decision Making

The landscape of complex engineered systems is rapidly evolving, from smart manufacturing facilities to next-generation transportation vehicles. As these systems become increasingly sophisticated and interconnected, the need for advanced health management systems grows ever more critical. These systems must go beyond simple monitoring, actively predicting potential failures before they occur. This paradigm shift from fixed maintenance schedules to condition-based predictions is key to optimizing system performance, enhancing safety, and paving the way for autonomous decision-making across various industries. Whether in industrial processes, energy systems, or advanced transportation, the ability to anticipate and prevent failures is becoming a cornerstone of operational excellence. To accurately predict the future health of any complex system, knowledge of its current health state and future operational conditions is essential. Recent advancements in data-driven algorithms have generated growing interest in artificial intelligence for industrial applications. However, the limitations of pure data-driven methods, particularly in industries where data acquisition is costly and limited, have become apparent. This has led to a focus on blending physics with data-driven algorithms, mitigating the drawbacks of both approaches while emphasizing their respective advantages. This research proposes a novel framework for integrating physics-based performance models with deep learning algorithms for the prognostics of complex safety-critical systems. In this approach, physics-based models serve as a blueprint, capturing fundamental system behaviors, while deep learning algorithms, leveraging real-world sensor data, fill in gaps and identify subtle patterns indicative of potential problems. This hybrid methodology, utilizing techniques such as Physics-Informed Neural Networks (PINNs), offers a powerful solution for predicting system health. By fusing domain knowledge with data-driven insights, this approach promises more accurate, adaptable, and reliable models for health prediction. The resulting framework is versatile, applicable across various sectors including aerospace, manufacturing, and energy systems, ultimately contributing to safer, more efficient operations in our increasingly complex technological landscape.

Diagnostics↗

NASA NTRS2006

Emerging technologies for V&V of ISHM software for space exploration

Systems1,2 required to exhibit high operational reliability often rely on some form of fault protection to recognize and respond to faults, preventing faults' escalation to catastrophic failures. Integrated System Health Management (ISHM) extends the functionality of fault protection to both scale to more complex systems (and systems of systems), and to maintain capability rather than just avert catastrophe. Forms of ISHM have been utilized to good effect in the maintenance phase of systems' total lifecycles (often referred to as 'condition-based mainte-nance'), but less so in a 'fault protection' role during actual operations. One of the impediments to such use lies in the challenges of verification, validation and certification of ISHM systems themselves. This paper makes the case that state-of-the-practice V&V and certification techniques will not suffice for emerging forms of ISHM systems; however, a number of maturing software engineering assurance technologies show particular promise for addressing these ISHM V&V challenges.

fault detection, isolation, and recovery↗