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NASA NTRS2014

Application of Fault Management Theory to the Quantitative Selection of a Launch Vehicle Abort Trigger Suite

The theory of System Health Management (SHM) and of its operational subset Fault Management (FM) states that FM is implemented as a "meta" control loop, known as an FM Control Loop (FMCL). The FMCL detects that all or part of a system is now failed, or in the future will fail (that is, cannot be controlled within acceptable limits to achieve its objectives), and takes a control action (a response) to return the system to a controllable state. In terms of control theory, the effectiveness of each FMCL is estimated based on its ability to correctly estimate the system state, and on the speed of its response to the current or impending failure effects. This paper describes how this theory has been successfully applied on the National Aeronautics and Space Administration's (NASA) Space Launch System (SLS) Program to quantitatively estimate the effectiveness of proposed abort triggers so as to select the most effective suite to protect the astronauts from catastrophic failure of the SLS. The premise behind this process is to be able to quantitatively provide the value versus risk trade‐off for any given abort trigger, allowing decision makers to make more informed decisions. All current and planned crewed launch vehicles have some form of vehicle health management system integrated with an emergency launch abort system to ensure crew safety. While the design can vary, the underlying principle is the same: detect imminent catastrophic vehicle failure, initiate launch abort, and extract the crew to safety. Abort triggers are the detection mechanisms that identify that a catastrophic launch vehicle failure is occurring or is imminent and cause the initiation of a notification to the crew vehicle that the escape system must be activated. While ensuring that the abort triggers provide this function, designers must also ensure that the abort triggers do not signal that a catastrophic failure is imminent when in fact the launch vehicle can successfully achieve orbit. That is, the abort triggers must have low false negative rates to be sure that real crew‐threatening failures are detected, and also low false positive rates to ensure that the crew does not abort from non‐crew‐threatening launch vehicle behaviors. The analysis process described in this paper is a compilation of over six years of lessons learned and refinements from experiences developing abort triggers for NASA's Constellation Program (Ares I Project) and the SLS Program, as well as the simultaneous development of SHM/FM theory. The paper will describe the abort analysis concepts and process, developed in conjunction with SLS Safety and Mission Assurance (S&MA) to define a common set of mission phase, failure scenario, and Loss of Mission Environment (LOME) combinations upon which the SLS Loss of Mission (LOM) Probabilistic Risk Assessment (PRA) models are built. This abort analysis also requires strong coordination with the Multi‐Purpose Crew Vehicle (MPCV) and SLS Structures and Environments (STE) to formulate a series of abortability tables that encapsulate explosion dynamics over the ascent mission phase. The design and assessment of abort conditions and triggers to estimate their Loss of Crew (LOC) Benefits also requires in‐depth integration with other groups, including Avionics, Guidance, Navigation and Control(GN&C), the Crew Office, Mission Operations, and Ground Systems. The outputs of this analysis are a critical input to SLS S&MA's LOC PRA models. The process described here may well be the first full quantitative application of SHM/FM theory to the selection of a sensor suite for any aerospace system.

Lo, Yunnhon↗

NASA NTRSDate not supplied

Advancement of Entry System Modeling to Support Exploration of Giant Planets

This paper describes NASA’s efforts to advance entry system modeling and simulation capabilities to support future exploration of Giant planets. The Giant planets are key destinations of interest to the planetary science community for their potential to provide insight into the formation and evolution of our Solar System, as well as extrasolar planetary systems. To date, the Galileo atmospheric probe is the only purpose-built entry probe to a Giant planet. Post-flight analysis of Galileo’s performance showed that there was significant recession of the thermal protection system (TPS), well beyond what was anticipated on the flank, and this was due in part to insufficiently accurate capability for estimating the flight environment and TPS response. While Galileo ultimately survived its flight, the example serves to highlight the great challenge of designing successful missions for environments that are poorly understood or where models have not yet been validated. An important means to reduce mission risks is the incorporation of physics-based modeling with well-quantified uncertainties. The emphasis on physics-based modeling – in contrast to empirically-driven models – is motivated by the fact that it is impossible to completely replicate entry environments through ground tests and, therefore, extrapolation to the flight environment is required. Basing analysis in fundamental physics removes the bias of ground test limitations, though one must then be careful to properly characterize model inputs, simplifying assumptions, and the limits wherein the model is valid. NASA’s Entry Systems Modeling (ESM) Project is tasked with investigating such considerations for planetary science missions across the Solar System, and in recent years has begun to do so for Giant planets. The most distinctive features of the Giant planets, from an entry system perspective, are the atmospheres composed primarily of hydrogen and helium. The entry velocities of proposed missions are generally very large and can therefore be expected to result in significant convective and radiative heating generated by the vehicle’s shock layer. Yet thermochemical behavior of the hydrogen-helium system is not well understood under such conditions. The ESM project is leading efforts to develop accurate thermochemical databases based on state-of-the-art measurements in the Electric Arc Shock Tube and detailed computational chemistry. The large heat fluxes anticipated by missions has driven interest in new TPS materials, in particular woven materials, which may be enabling but have never been flown before. Consequently, multiscale models are in development to describe properties and performance of the materials from micro- to system-scale. The goal is to not only provide accurate thermal response but also to inform thermostructural reliability predictions for extreme entries. Additionally, new computational models have been developed to evaluate performance of non-destructive evaluation techniques which are vital to establishing acceptance of systems to be free of manufacturing faults like material cracking, voids, and debonding. Finally, in the area of guidance and control, aerocapture has been shown conceptually to provide a number of mission benefits, including reducing transit time and increasing payload fraction. The ESM project is building a launch-to-landing trajectory simulation capability to enable detailed studies of aerocapture maneuvers in the context of Giant planets missions. The final presentation and paper will describe each of these topics in detail, including discussion of specific gaps and the technical approach to solving them. In addition, the final paper will briefly discuss ongoing coordination between ESM project work and an ESA-funded technology development activity comprised of validation testing in the Oxford T6, IRS PWK and IST ESTHER tunnels, as well as state-to-state modeling of the shock layer to better represent non-Boltzmann energy distributions leading to non-equilibrium radiation.

Entry systems↗

DOE OSTI2025

Quantitative Risk Assessment for Fuel Cell Electric Bus Hydrogen Storage and Refueling Facility

It is necessary to understand the safety implications and risk mitigation options for fuel cell electric bus fleet deployment, especially for related facilities responsible for operations such as production, storage, compression, and dispensing of hydrogen for use by the buses. In this report, we present a quantitative risk assessment for a potential fuel cell electric bus fleet that was motivated by efforts to improve resilience at the Portland International Airport but can be applicable to a range of hydrogen case studies and use cases. We estimated risk for a facility that produces, stores, compresses, and dispenses hydrogen for the fleet of buses, with a focus on individual risk to people in terms of annual frequency of fatality. We considered the frequency of hydrogen leaks that could result in harmful physical outcomes like jet fires or explosions, and the consequences of those outcomes for people. We created customized fault trees to calculate the frequencies of different sizes of leaks and event sequence diagrams to calculate ignition probabilities for the various leak sizes. We also leveraged the HyRAM+ toolkit to use these inputs to calculate overall risk for the facility, which we separated into one section responsible for producing, storing, and compressing hydrogen, and one section responsible for dispensing the hydrogen to the buses. We found that the dispensing area seemed to have a higher risk than the production/storage/compression area of the facility, largely because of the inclusion of a component with a high leak frequency (the heat exchanger used to cool the hydrogen before entering the vehicle, to prevent overheating and expansion of hydrogen in the onboard tank). For the example production and refueling facility we evaluated and the data we used for the analysis, the leak frequency had a larger impact on the risk differences between the two sections on the facility, compared to the physical outcome consequence, which was slightly different due to the varying fuel conditions, but not substantially different. Actions can be taken to prevent these hazards (e.g., lowering leak frequencies in system components) or to mitigate the consequences if they do occur (e.g., installing barriers to protect people if ignition events occur). The choice of which actions to take depends not only on safety considerations but also on space, time, staffing, feasibility, and financial constraints. Therefore, the quantitative risk assessment approach can help understand relative risk contributions from different components, leak sizes, consequences, and human actions, to prioritize risk reduction strategies and balance these parameters. The outcomes of this report may be useful for a variety of stakeholders working in the hydrogen, transportation, vehicle, and aviation sector, including those responsible for aspects like facility design, operations, and regulations. There is not a single value of risk that determines whether a hypothetical system is “safe” or not. The insights about risk mitigations may be leveraged, and the quantitative risk assessment approach can be applied to other case studies to understand risk priorities and contributions specific to different FCEB and hydrogen facility uses.

08 HYDROGEN↗

NASA NTRS2022

Electrical Ground Support Equipment for the Sampling Caching System of the Mars 2020 Rover

In this work we describe in detail the architecture, design, testing and operation of the Electrical Ground Support Equipment (EGSE) “Blue Box” used to test and validate the Sampling Caching System (SCS) of the Mars 2020 Perseverance rover. The Blue Box architecture is centered around COTS motor controllers and COTS input-output modules communicating over an EtherCAT bus. A custom, low-level safety subsystem ensures no harm can be done to the flight articles. The modular architecture of the EGSE reduces cost and complexity while expediting assembly time. The Blue Box drives the 19 actuators of the SCS which span the main robotic arm, the corer system, the internal sample handling arm, the sample tube sealing system and the gas dust removal tool; mimicking the Rover Motor Control Assembly (RMCA). Due to the limited availability of RMCA’s, the EGSE enabled and performed the bulk of testing activities for SCS. The majority of the SCS actuators are composed of a 3-phase DC brushless motors, hall sensors for commutation, dual resolvers for output angular measurement, brakes, heaters and platinum thermistors. Additionally, the EGSE read 12 strain gauges forming part of a force torque sensor, and switches used for external positioning references. Over the 3-year span of the V&V campaign for the SCS, over 32 EGSE systems were built, tested and deployed to test venues at JPL and externally. The EGSE tested several families of the SCS subsystem, ranging from engineering units, life test units and two flight units. Test venues that this EGSE supported included lab benches, ultra-clean cleanrooms, ATLO facilities, and thermal vacuum chambers. Together with the test software systems, SSDEV and SSDEV-ECAT, the Blue Box EGSE enabled the team to efficiently test flight hardware and flight software together. We go over the safety features and fault management techniques employed to protect flight hardware. The effects of the long, 50-feet, EGSE harnesses on motor performance, EMI, electrical noise, and motor control performance are explained. Mitigations to these unwanted effects, including shielding strategy and inductance compensation, are summarized. We go over an excerpt of notable anomalies that this EGSE suffered through its operation, along with investigations and resolutions. Lessons learned, areas of improvement as part of future work, and recommendations for future implementations for similar EGSE’s, are shared.

Levine, Dan↗

NASA NTRS2013

Development of the Orion Crew-Service Module Umbilical Retention and Release Mechanism

The Orion CSM umbilical retention and release mechanism supports and protects all of the cross-module commodities between the spacecrafts crew and service modules. These commodities include explosive transfer lines, wiring for power and data, and flexible hoses for ground purge and life support systems. The mechanism employs a single separation interface which is retained with pyrotechnically actuated separation bolts and supports roughly two dozen electrical and fluid connectors. When module separation is commanded, either for nominal on-orbit CONOPS or in the event of an abort, the mechanism must release the separation interface and sever all commodity connections within milliseconds of command receipt. There are a number of unique and novel aspects of the design solution developed by the Orion mechanisms team. The design is highly modular and can easily be adapted to other vehiclesmodules and alternate commodity sets. It will be flight tested during Orions Exploration Flight Test 1 (EFT-1) in 2014, and the Orion team anticipates reuse of the design for all future missions. The design packages fluid, electrical, and ordnance disconnects in a single separation interface. It supports abort separations even in cases where aerodynamic loading prevents the deployment of the umbilical arm. Unlike the Apollo CSM umbilical which was a destructive separation device, the Orion design is resettable and flight units can be tested for separation performance prior to flight.Initial development testing of the mechanisms separation interface resulted in binding failures due to connector misalignments. The separation interface was redesigned with a robust linear guide system, and the connector separation and boom deployment were separated into two discretely sequenced events. These changes addressed the root cause of the binding failure by providing better control of connector alignment. The new design was tuned and validated analytically via Monte Carlo simulation. The analytical validation was followed by a repeat of the initial test suite plus test cases at thermal extremes and test cases with imposed mechanical failures demonstrating fault tolerance. The mechanism was then exposed to the qualification vibration environment. Finally, separation testing was performed at full speed with live ordnance.All tests of the redesigned mechanism resulted in successful separation of the umbilical interface with adequate force margins and timing. The test data showed good agreement with the predictions of the Monte Carlo simulation. The simulation proved invaluable due to the number of variables affecting the separation and the uncertainty associated with each. The simulation allowed for rapid assessment of numerous trades and contingency scenarios, and can be easily reconfigured for varying commodity sets and connector layouts.

Separation↗

NASA NTRS2012

Modular, Autonomous Command and Data Handling Software with Built-In Simulation and Test

The spacecraft system that plays the greatest role throughout the program lifecycle is the Command and Data Handling System (C&DH), along with the associated algorithms and software. The C&DH takes on this role as cost driver because it is the brains of the spacecraft and is the element of the system that is primarily responsible for the integration and interoperability of all spacecraft subsystems. During design and development, many activities associated with mission design, system engineering, and subsystem development result in products that are directly supported by the C&DH, such as interfaces, algorithms, flight software (FSW), and parameter sets. A modular system architecture has been developed that provides a means for rapid spacecraft assembly, test, and integration. This modular C&DH software architecture, which can be targeted and adapted to a wide variety of spacecraft architectures, payloads, and mission requirements, eliminates the current practice of rewriting the spacecraft software and test environment for every mission. This software allows missionspecific software and algorithms to be rapidly integrated and tested, significantly decreasing time involved in the software development cycle. Additionally, the FSW includes an Onboard Dynamic Simulation System (ODySSy) that allows the C&DH software to support rapid integration and test. With this solution, the C&DH software capabilities will encompass all phases of the spacecraft lifecycle. ODySSy is an on-board simulation capability built directly into the FSW that provides dynamic built-in test capabilities as soon as the FSW image is loaded onto the processor. It includes a six-degrees- of-freedom, high-fidelity simulation that allows complete closed-loop and hardware-in-the-loop testing of a spacecraft in a ground processing environment without any additional external stimuli. ODySSy can intercept and modify sensor inputs using mathematical sensor models, and can intercept and respond to actuator commands. ODySSy integration is unique in that it allows testing of actual mission sequences on the flight vehicle while the spacecraft is in various stages of assembly, test, and launch operations all without any external support equipment or simulators. The ODySSy component of the FSW significantly decreases the time required for integration and test by providing an automated, standardized, and modular approach to integrated avionics and component interface and functional verification. ODySSy further provides the capability for on-orbit support in the form of autonomous mission planning and fault protection.

Cuseo, John↗

NASA NTRS2009

NASA Tech Briefs, May 2009

Topics covered include: Valve-"Health"-Monitoring System; Microstrip Antenna for Remote Sensing of Soil Moisture and Sea Surface Salinity; Biomedical Wireless Ambulatory Crew Monitor; Wireless Avionics Packet to Support Fault Tolerance for Flight Applications; Aerobot Autonomy Architecture; Submillimeter Confocal Imaging Active Module; Traveling-Wave Maser for 32 GHz; System Synchronizes Recordings from Separated Video Cameras; Piecewise-Planar Parabolic Reflectarray Antenna; Reducing Interference in ATC Voice Communication; EOS MLS Level 1B Data Processing, Version 2.2; Auto-Generated Semantic Processing Services; Geospatial Authentication; Maneuver Automation Software; Event Driven Messaging with Role-Based Subscriptions; Estimating Relative Positions of Outer-Space Structures; Fabricating PFPE Membranes for Capillary Electrophoresis; Linear Actuator Has Long Stroke and High Resolution; Installing a Test Tap on a Metal Battery Case; Fabricating PFPE Membranes for Microfluidic Valves and Pumps; Room-Temperature-Cured Copolymers for Lithium Battery Gel Electrolytes; Catalysts for Efficient Production of Carbon Nanotubes; Amorphous Silk Fibroin Membranes for Separation of CO2; "Zero-Mass" Noninvasive Pressure Transducers; Radial-Electric-Field Piezoelectric Diaphragm Pumps; Ejector-Enhanced, Pulsed, Pressure-Gain Combustor; Suppressing Ghost Diffraction in E-Beam-Written Gratings; Target-Tracking Camera for a Metrology System; Polarimetric Imaging using Two Photoelastic Modulators; Miniature Wide-Angle Lens for Small-Pixel Electronic Camera; Modal Filters for Infrared Interferometry; Mo(3)Sb(7-x)Te(x) for Thermoelectric Power Generation; Two-Dimensional Quantum Model of a Nanotransistor; Scanning Miniature Microscopes without Lenses; Manipulating Neutral Atoms in Chip-Based Magnetic Traps; Expansion Compression Contacts for Thermoelectric Legs; Processing Electromyographic Signals to Recognize Words; Physical Principle for Generation of Randomness; DSN Beowulf Cluster-Based VLBI Correlator; Hybrid NN/SVM Computational System for Optimizing Designs; Criteria for Modeling in LES of Multicomponent Fuel Flow; Computerized Machine for Cutting Space Shuttle Thermal Tiles; Orbiting Depot and Reusable Lander for Lunar Transportation; FPGA-Based Networked Phasemeter for a Heterodyne Interferometer; Aquarius Digital Processing Unit; Three-Dimensional Optical Coherence Tomography; Benchtop Antigen Detection Technique using Nanofiltration and Fluorescent Dyes; Isolation of Precursor Cells from Waste Solid Fat Tissue; Identification of Bacteria and Determination of Biological Indicators; Further Development of Scaffolds for Regeneration of Nerves; Chemically Assisted Photocatalytic Oxidation System; Use of Atomic Oxygen for Increased Water Contact Angles of Various Polymers for Biomedical Applications; Crashworthy Seats Would Afford Superior Protection; Open-Access, Low-Magnetic-Field MRI System for Lung Research; Microfluidic Mixing Technology for a Universal Health Sensor; Microfluidic Extraction of Biomarkers using Water as Solvent; Microwell Arrays for Studying Many Individual Cells; Droplet-Based Production of Liposomes; and Identifying and Inactivating Bacterial Spores

Source record↗