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Knowledge Discovery for Early Failure Assessment of Complex Engineered Systems Using Natural Language Processing

Emerging complex engineered systems may have unexpected safety issues due to novel operational environments, increasing autonomy, human-machine interaction, and other factors. To prevent failures in operation or testing that necessitate costly redesign, it is desirable to predict likely failure modes early in the design process. Information about past engineering failures in natural language format presents one possible solution by enabling the retrieval of information that can inform new designs. However, identifying documents containing usable information and extracting the required information can be prohibitively time-consuming when implemented at scale. In this research, an automated natural language processing (NLP) framework is proposed to discover relevant knowledge from documents containing failure-related design information. The framework is applied to NASA’s Lessons Learned Information System (LLIS),which is publicly available. Documents containing usable information are filtered using two different NLP-based models. Next, from the identified usable documents, a failure taxonomy is extracted using a partitioned hierarchical topic modeling approach. Partitions of the document describe different sections of the failure taxonomy – i.e., failure, cause of failure, and recommendations – as indicated by the structure of the original document. The extracted failure taxonomy can be leveraged in early design failure assessment methods. Moreover, the framework can be used to identify documents containing usable failure-related design information from other databases and extract relevant information from these documents.

Documentation and Information Science

Expanded Guidance for NASA Systems Engineering. Volume 1: Systems Engineering Practices

This document is intended to provide general guidance and information on systems engineering that will be useful to the NASA community. It provides a generic description of Systems Engineering (SE) as it should be applied throughout NASA. A goal of the expanded guidance is to increase awareness and consistency across the Agency and advance the practice of SE. This guidance provides perspectives relevant to NASA and data particular to NASA. This expanded guidance should be used as a companion for implementing NPR 7123.1, Systems Engineering Processes and Requirements, the Rev 2 version of SP-6105, and the Center-specific handbooks and directives developed for implementing systems engineering at NASA. It provides a companion reference book for the various systems engineering-related training being offered under NASA's auspices.

Steven R Hirshorn

An Agile-Like Approach to Hardware Development: The Ejectable Data Recorder (EDR) for Orion's Ascent Abort 2 (AA-2) Test Flight

On July 2, 2019, the Ascent Abort 2 (AA-2) Flight Test Vehicle was launched from Cape Canaveral, with the goal of demonstrating the performance of Orion’s Launch Abort System (LAS) and collecting data from hundreds of sensors throughout the vehicle. The data collected during this test flight is of paramount importance, as it will be used to certify the Orion vehicle for human spaceflight. Originally, the data was to be downlinked via a single string network of antennas on the LAS, with the associated risk of potential data dropouts, as well as loss of data once the LAS was jettisoned. Thus, additional antennas were added onto the crew module (CM) to support data downlink post-LAS jettison, a buffer rebroadcast capability was added to fill in any gaps in data downlink transmissions, and an ejectable data recorder (EDR) subsystem was added to the CM as a redundant measure to collect all the instrumentation data. The EDR subsystem was added to the project about one year after the project commenced, which significantly reduced the available development time when compared with the other subsystems of the AA-2 Test Flight. The project was further accelerated by six months, around the critical design review gate. Due to the schedule compression challenge and the fact that the EDR subsystem was a backup system and not flight critical, the EDR subsystem was further challenged to find a new and more efficient way to develop hardware. Thus, the EDR subsystem experimented with different management and systems engineering processes, team sizes, communication methods, and tools. Some examples are novel uses of SharePoint as a Data-centric Project Management & Systems Engineering environment, a continuous testing approach through the lifecycle, and a Skunkworks approach to managing the team. The EDR subsystem blended Commercial Off The Shelf (COTS) hardware with in-house developed hardware and software to create a novel data retrieval capability. The capability evolved rapidly through a hardware in the loop simulation environment that enabled incremental component updates for not only the EDR subsystem but across the entire Crew Module. This paper will present an overview of how the EDR subsystem was managed and compare it to an Agile approach to managing projects. The paper will further provide a recommended approach to future Agile-like hardware development that incorporates lessons learned from the EDR experience.

Agile

Software Engineering Laboratory (SEL) cleanroom process model

The Software Engineering Laboratory (SEL) cleanroom process model is described. The term 'cleanroom' originates in the integrated circuit (IC) production process, where IC's are assembled in dust free 'clean rooms' to prevent the destructive effects of dust. When applying the clean room methodology to the development of software systems, the primary focus is on software defect prevention rather than defect removal. The model is based on data and analysis from previous cleanroom efforts within the SEL and is tailored to serve as a guideline in applying the methodology to future production software efforts. The phases that are part of the process model life cycle from the delivery of requirements to the start of acceptance testing are described. For each defined phase, a set of specific activities is discussed, and the appropriate data flow is described. Pertinent managerial issues, key similarities and differences between the SEL's cleanroom process model and the standard development approach used on SEL projects, and significant lessons learned from prior cleanroom projects are presented. It is intended that the process model described here will be further tailored as additional SEL cleanroom projects are analyzed.

Green, Scott

The GA sulfur-iodine water-splitting process - A status report

The development of a sulfur-iodine thermal water splitting cycle is described. The process features a 50% thermal efficiency, plus all liquid and gas handling. Basic chemical investigations comprised the development of multitemperature and multistage sulfuric acid boost reactors, defining the phase behavior of the HI/I2/H2O/H3PO4 mixtures, and development of a decomposition process for hydrogen iodide in the liquid phase. Initial process engineering studies have led to a 47% efficiency, improvements of 2% projected, followed by coupling high-temperature solar concentrators to the splitting processes to reduce power requirements. Conceptual flowsheets developed from bench models are provided; materials investigations have concentrated on candidates which can withstand corrosive mixtures at temperatures up to 400 deg K, with Hastelloy C-276 exhibiting the best properties for containment and heat exchange to I2.

Besenbruch, G. E.

Automatic building energy model development and debugging using large language models agentic workflow

Building energy modeling (BEM) is a complex process that demands significant time and expertise, limiting its broader application in building design and operations. While Large Language Models (LLMs) agentic workflow have facilitated complex engineering processes, their application in BEM has not been specifically explored. This paper investigates the feasibility of automating BEM using LLM agentic workflow. Here, we developed a generic LLM-planning-based workflow that takes a building description as input and generates an error-free EnergyPlus building energy model. Our robust workflow includes four core agents: 1) Building Description Pre-Processing, 2) IDF Object Information Extraction, 3) Single IDF Object Generator Suite, and 4) IDF Debugging Agent. These agents divide the complex tasks into manageable sub-steps, enabling LLMs to generate accurate and reliable results at each stage. The case study demonstrates the successful translation of a building description into an error-free EnergyPlus model for the iUnit modular building at the National Renewable Energy Laboratory. The effectiveness of our workflow surpasses: 1) naive prompt engineering, 2) other LLM-based workflows, and 3) manual modeling, in terms of accuracy, reliability, and time efficiency. The paper concludes with a discussion on the interplay between foundational models and LLM agent planning design, advocating for the use of fine-tuned, specialized models to advance this field.

97 MATHEMATICS AND COMPUTING

BERT-based Topic Modeling and Information Retrieval to Support Fishbone Diagramming for Safe Integration of Unmanned Aircraft Systems in Wildfire Response

Recent concepts for emerging wildfire response operations have included unmanned aircraft systems (UAS) due to their increasing accessibility and capabilities. To integrate UAS into wildfire response safely, researchers have studied the use of large repositories of historic incident reports to improve the scope of root cause analysis. Recent work has emphasized applying state-of-the-art natural language processing techniques to extract useful information from these repositories. However, it has not yet been studied how these results can be interpreted and integrated into the systems engineering process. In this work, we propose a process in which Bidirectional Encoder Representations from Transformers (BERT)-based topic modeling and information retrieval are applied to a relevant set of documents in order to support the development of a fishbone diagram in a semiautomated process. High-level themes in the document set are identified using topic modeling, which are then refined and interpreted by a human analyst. Then, the themes are used to guide a finer search using information retrieval, which returns specific incident reports of relevance. This provides traceability to specific incidents as well as broader categorizations that comprise the fishbone branches. We apply the proposed process to relevant documents from NASA’s Aviation Safety Reporting System (ASRS). The proposed process is widely applicable when relevant documents are available, and the results from this study will be useful to identifying potential causes of wildfire response UAS incidents.

hazard analysis

BERT-based Topic Modeling and Information Retrieval to Support Fishbone Diagramming for Safe Integration of Unmanned Aircraft Systems in Wildfire Response

Recent concepts for emerging wildfire response operations have included unmanned aircraft systems (UAS) due to their increasing accessibility and capabilities. To integrate UAS into wildfire response safely, researchers have studied the use of large repositories of historic incident reports to improve the scope of root cause analysis. Recent work has emphasized applying state-of-the-art natural language processing techniques to extract useful information from these repositories. However, it has not yet been studied how these results can be interpreted and integrated into the systems engineering process. In this work, we propose a process in which Bidirectional Encoder Representations from Transformers (BERT)-based topic modeling and information retrieval are applied to a relevant set of documents in order to support the development of a fishbone diagram in a semiautomated process. High-level themes in the document set are identified using topic modeling, which are then refined and interpreted by a human analyst. Then, the themes are used to guide a finer search using information retrieval, which returns specific incident reports of relevance. This provides traceability to specific incidents as well as broader categorizations that comprise the fishbone branches. We apply the proposed process to relevant documents from NASA’s Aviation Safety Reporting System (ASRS). The proposed process is widely applicable when relevant documents are available, and the results from this study will be useful to identifying potential causes of wildfire response UAS incidents.

hazard analysis

BERT-Based Topic Modeling and Information Retrieval to Support Fishbone Diagramming for Safe Integration of Unmanned Aircraft Systems in Wildfire Response

Recent concepts for emerging wildfire response operations have included unmanned aircraft systems (UAS) due to their increasing accessibility and capabilities. To integrate UAS into wildfire response safely, researchers have studied the use of large repositories of historic incident reports to improve the scope of root cause analysis. Recent work has emphasized applying state-of-the-art natural language processing techniques to extract useful information from these repositories. However, it has not yet been studied how these results can be interpreted and integrated into the systems engineering process. In this work, we propose a process in which Bidirectional Encoder Representations from Transformers (BERT)-based topic modeling and information retrieval are applied to a relevant set of documents in order to support the development of a fishbone diagram in a semiautomated process. High-level themes in the document set are identified using topic modeling, which are then refined and interpreted by a human analyst. Then, the themes are used to guide a finer search using information retrieval, which returns specific incident reports of relevance. This provides traceability to specific incidents as well as broader categorizations that comprise the fishbone branches. We apply the proposed process to relevant documents from NASA’s Aviation Safety Reporting System (ASRS). The proposed process is widely applicable when relevant documents are available, and the results from this study will be useful to identifying potential causes of wildfire response UAS incidents.

Hazard analysis

Aircraft Engine-Monitoring System And Display

Proposed Engine Health Monitoring System and Display (EHMSD) provides enhanced means for pilot to control and monitor performances of engines. Processes raw sensor data into information meaningful to pilot. Provides graphical information about performance capabilities, current performance, and operational conditions in components or subsystems of engines. Provides means to control engine thrust directly and innovative means to monitor performance of engine system rapidly and reliably. Features reduce pilot workload and increase operational safety.

Abbott, Terence S.

Global Design Optimization for Aerodynamics and Rocket Propulsion Components

Modern computational and experimental tools for aerodynamics and propulsion applications have matured to a stage where they can provide substantial insight into engineering processes involving fluid flows, and can be fruitfully utilized to help improve the design of practical devices. In particular, rapid and continuous development in aerospace engineering demands that new design concepts be regularly proposed to meet goals for increased performance, robustness and safety while concurrently decreasing cost. To date, the majority of the effort in design optimization of fluid dynamics has relied on gradient-based search algorithms. Global optimization methods can utilize the information collected from various sources and by different tools. These methods offer multi-criterion optimization, handle the existence of multiple design points and trade-offs via insight into the entire design space, can easily perform tasks in parallel, and are often effective in filtering the noise intrinsic to numerical and experimental data. However, a successful application of the global optimization method needs to address issues related to data requirements with an increase in the number of design variables, and methods for predicting the model performance. In this article, we review recent progress made in establishing suitable global optimization techniques employing neural network and polynomial-based response surface methodologies. Issues addressed include techniques for construction of the response surface, design of experiment techniques for supplying information in an economical manner, optimization procedures and multi-level techniques, and assessment of relative performance between polynomials and neural networks. Examples drawn from wing aerodynamics, turbulent diffuser flows, gas-gas injectors, and supersonic turbines are employed to help demonstrate the issues involved in an engineering design context. Both the usefulness of the existing knowledge to aid current design practices and the need for future research are identified.

Shyy, Wei

Ignition process in Diesel engines

This report analyzes the heating and vaporization process of fuel droplets in a compression-ignition engine on the basis of the theory of similitude - according to which, the period for heating and complete vaporization of the average size fuel drop is only a fraction of the actually observed ignition lag. The result is that ignition takes place in the fuel vapor air mixture rather than on the surface of the drop. The theoretical result is in accord with the experimental observations by Rothrock and Waldron. The combustion shock occurring at lower terminal compression temperature, especially in the combustion of coal-tar oil, is attributable to a simultaneous igniting of a larger fuel-vapor volume formed prior to ignition.

Wentzel, W

Functional Fault Model Development Process to Support Design Analysis and Operational Assessment

A functional fault model (FFM) is an abstract representation of the failure space of a given system. As such, it simulates the propagation of failure effects along paths between the origin of the system failure modes and points within the system capable of observing the failure effects. As a result, FFMs may be used to diagnose the presence of failures in the modeled system. FFMs necessarily contain a significant amount of information about the design, operations, and failure modes and effects. One of the important benefits of FFMs is that they may be qualitative, rather than quantitative and, as a result, may be implemented early in the design process when there is more potential to positively impact the system design. FFMs may therefore be developed and matured throughout the monitored system's design process and may subsequently be used to provide real-time diagnostic assessments that support system operations. This paper provides an overview of a generalized NASA process that is being used to develop and apply FFMs. FFM technology has been evolving for more than 25 years. The FFM development process presented in this paper was refined during NASA's Ares I, Space Launch System, and Ground Systems Development and Operations programs (i.e., from about 2007 to the present). Process refinement took place as new modeling, analysis, and verification tools were created to enhance FFM capabilities. In this paper, standard elements of a model development process (i.e., knowledge acquisition, conceptual design, implementation & verification, and application) are described within the context of FFMs. Further, newer tools and analytical capabilities that may benefit the broader systems engineering process are identified and briefly described. The discussion is intended as a high-level guide for future FFM modelers.

Verification

QATT: a Natural Language Interface for QPE

QATT, a natural language interface developed for the Qualitative Process Engine (QPE) system is presented. The major goal was to evaluate the use of a preexisting natural language understanding system designed to be tailored for query processing in multiple domains of application. The other goal of QATT is to provide a comfortable environment in which to query envisionments in order to gain insight into the qualitative behavior of physical systems. It is shown that the use of the preexisting system made possible the development of a reasonably useful interface in a few months.

White, Douglas Robert-Graham

Applying Technology Ranking and Systems Engineering in Advanced Life Support

According to the Advanced Life Support (ALS) Program Plan, the Systems Modeling and Analysis Project (SMAP) has two important tasks: 1) prioritizing investments in ALS Research and Technology Development (R&TD), and 2) guiding the evolution of ALS systems. Investments could be prioritized simply by independently ranking different technologies, but we should also consider a technology's impact on system design. Guiding future ALS systems will require SMAP to consider many aspects of systems engineering. R&TD investments can be prioritized using familiar methods for ranking technology. The first step is gathering data on technology performance, safety, readiness level, and cost. Then the technologies are ranked using metrics or by decision analysis using net present economic value. The R&TD portfolio can be optimized to provide the maximum expected payoff in the face of uncertain future events. But more is needed. The optimum ALS system can not be designed simply by selecting the best technology for each predefined subsystem. Incorporating a new technology, such as food plants, can change the specifications of other subsystems, such as air regeneration. Systems must be designed top-down starting from system objectives, not bottom-up from selected technologies. The familiar top-down systems engineering process includes defining mission objectives, mission design, system specification, technology analysis, preliminary design, and detail design. Technology selection is only one part of systems analysis and engineering, and it is strongly related to the subsystem definitions. ALS systems should be designed using top-down systems engineering. R&TD technology selection should consider how the technology affects ALS system design. Technology ranking is useful but it is only a small part of systems engineering.

Jones, Harry

Systems Engineering and Integration for Advanced Life Support System and HST

Systems engineering (SE) discipline has revolutionized the way engineers and managers think about solving issues related to design of complex systems: With continued development of state-of-the-art technologies, systems are becoming more complex and therefore, a systematic approach is essential to control and manage their integrated design and development. This complexity is driven from integration issues. In this case, subsystems must interact with one another in order to achieve integration objectives, and also achieve the overall system's required performance. Systems engineering process addresses these issues at multiple levels. It is a technology and management process dedicated to controlling all aspects of system life cycle to assure integration at all levels. The Advanced Integration Matrix (AIM) project serves as the systems engineering and integration function for the Human Support Technology (HST) program. AIM provides means for integrated test facilities and personnel for performance trade studies, analyses, integrated models, test results, and validated requirements of the integration of HST. The goal of AIM is to address systems-level integration issues for exploration missions. It will use an incremental systems integration approach to yield technologies, baselines for further development, and possible breakthrough concepts in the areas of technological and organizational interfaces, total information flow, system wide controls, technical synergism, mission operations protocols and procedures, and human-machine interfaces.

Kamarani, Ali K.

Functional Fault Model Development Process to Support Design Analysis and Operational Assessment

A functional fault model (FFM) is an abstract representation of the failure space of a givensystem. As such, it simulates the propagation of failure effects along paths between the origin ofthe system failure modes and points within the system capable of observing the failure effects. Asa result, FFMs may be used to diagnose the presence of failures in the modeled system. FFMsnecessarily contain a significant amount of information about the design, operations, and failuremodes and effects. One of the important benefits of FFMs is that they may be qualitative, ratherthan quantitative and, as a result, may be implemented early in the design process when there ismore potential to positively impact the system design. FFMs may therefore be developed andmatured throughout the monitored system's design process and may subsequently be used toprovide real-time diagnostic assessments that support system operations. This paper provides anoverview of a generalized NASA process that is being used to develop and apply FFMs. FFMtechnology has been evolving for more than 25 years. The FFM development process presented inthis paper was refined during NASA's Ares I, Space Launch System, and Ground SystemsDevelopment and Operations programs (i.e., from about 2007 to the present). Process refinementtook place as new modeling, analysis, and verification tools were created to enhance FFMcapabilities. In this paper, standard elements of a model development process (i.e., knowledgeacquisition, conceptual design, implementation & verification, and application) are describedwithin the context of FFMs. Further, newer tools and analytical capabilities that may benefit thebroader systems engineering process are identified and briefly described. The discussion isintended as a high-level guide for future FFM modelers.

Melcher, Kevin J.