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At least 253 records · Page 14

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NASA NTRS1988

Pyrotechnic system failures: Causes and prevention

Although pyrotechnics have successfully accomplished many critical mechanical spacecraft functions, such as ignition, severance, jettisoning and valving (excluding propulsion), failures continue to occur. Provided is a listing of 84 failures of pyrotechnic hardware with completed design over a 23-year period, compiled informally by experts from every NASA Center, as well as the Air Force Space Division and the Naval Surface Warfare Center. Analyses are presented as to when and where these failures occurred, their technical source or cause, followed by the reasons why and how these kinds of failures persist. The major contributor is a fundamental lack of understanding of the functional mechanisms of pyrotechnic devices and systems, followed by not recognizing pyrotechnics as an engineering technology, insufficient manpower with hands-on experience, too few test facilities, and inadequate guidelines and specifications for design, development, qualification and acceptance. Recommendations are made on both a managerial and technical basis to prevent failures, increase reliability, improve existing and future designs, and develop the technology to meet future requirements.

Bement, Laurence J.↗

NASA NTRS1988

Effect of model uncertainty on failure detection - The threshold selector

The performance of all failure detection, isolation, and accomodation (DIA) algorithms is influenced by the presence of model uncertainty. A unique framework is presented to incorporate a knowledge of modeling error in the analysis and design of failure detection systems. The tools being used are very similar to those in robust control theory. A concept is introduced called the threshold selector, which is a nonlinear inequality whose solution defines the set of detectable sensor failure signals. The threshold selector represents an innovative tool for analysis and synthesis of DIA algorithms. It identifies the optimal threshold to be used in innovations-based DIA algorithms. The optimal threshold is shown to be a function of the bound on modeling errors, the noise properties, the speed of DIA filters, and the classes of reference and failure signals. The size of the smallest detectable failure is also determined. The results are applied to a multivariable turbofan jet engine example, which demonstrates improvements compared to previous studies.

Emami-Naeini, Abbas↗

NASA NTRS1989

An investigation of gear mesh failure prediction techniques

A study was performed in which several gear failure prediction methods were investigated and applied to experimental data from a gear fatigue test apparatus. The primary objective was to provide a baseline understanding of the prediction methods and to evaluate their diagnostic capabilities. The methods investigated use the signal average in both the time and frequency domain to detect gear failure. Data from eleven gear fatigue tests were recorded at periodic time intervals as the gears were run from initiation to failure. Four major failure modes, consisting of heavy wear, tooth breakage, single pits, and distributed pitting were observed among the failed gears. Results show that the prediction methods were able to detect only those gear failures which involved heavy wear or distributed pitting. None of the methods could predict fatigue cracks, which resulted in tooth breakage, or single pits. It is suspected that the fatigue cracks were not detected because of limitations in data acquisition rather than in methodology. Additionally, the frequency response between the gear shaft and the transducer was found to significantly affect the vibration signal. The specific frequencies affected were filtered out of the signal average prior to application of the methods.

Zakrajsek, James J.↗

NASA NTRS1989

Characterization of failure processes in tungsten copper composites under fatigue loading conditions

A fractographic and metallographic investigation was performed on specimens of a tungsten fiber reinforced copper matrix composite (9 vol percent), which had experienced fatigue failures at elevated temperatures. Major failure modes and possible failure mechanisms, with an emphasis placed on characterizing fatigue damage accumulation, were determined. Metallography of specimens fatigued under isothermal cyclic loading suggested that fatigue damage initiates in the matrix. Cracks nucleated within the copper matrix at grain boundaries, and they propagated through cavity coalescence. The growing cracks subsequently interacted with the reinforcing tungsten fibers, producing a localized ductile fiber failure. Examinations of interrupted tests before final failure confirmed the suggested fatigue damage processes.

Kim, Yong-Suk↗

NASA NTRS1990

Rocket engine failure detection using system identification techiques

The theoretical foundation and application of two univariate failure detection algorithms to Space Shuttle Main Engine (SSME) test firing data is presented. Both algorithms were applied to data collected during steady state operation of the engine. One algorithm, the time series algorithm, is based on time series techniques and involves the computation of autoregressive models. Times series techniques have been previously applied to SSME data. The second algorithm is based on standard signal processing techniques. It consists of tracking the variations in the average signal power with time. The average signal power algorithm is a newly proposed SSME failure detection algorithm. Seven nominal test firings were used to develop failure indication thresholds for each algorithm. These thresholds were tested using four anomalous firings and one additional nominal firing. Both algorithms provided significantly earlier failure indication times than did the current redline limit system. Neither algorithm gave false failure indications for the nominal firing. The strengths and weaknesses of the two algorithms are discussed and compared. The average signal algorithm was found to have several advantages over the time series algorithm.

Meyer, Claudia M.↗

NASA NTRS1990

Probabilistic high cycle fatigue failure analysis with application to liquid propellant rocket engines

A probabilistic high cycle fatigue (HCF) failure analysis of a welded duct in a rocket engine of the Space Shuttle main engine class is described. A state-of-the-art HCF failure prediction method was used in a Monte Carlo simulation to generate a distribution of failure lives. A stochastic stress/life model is used for material characterization, and a composite stress history is generated for accurately deriving the stress cycles for the fatigue-damage calculations. The HCF failure model expresses fatigue life as a function of stochastic parameters including environment, loads, material properties, geometry, and model specification errors. A series of HCF failure life analyses were performed to study the impact of a fixed parameter and to assess the importance of each stochastic input parameter through marginal analyses.

Sutharshana, S.↗

NASA NTRS1990

Probabilistic low cycle fatigue failure analysis with application to liquid propellant rocket engines

A probabilistic Low Cycle Fatigue (LCF) failure analysis of a candidate turbine disk for use in a turbopump of a rocket engine of the Space Shuttle Main Engine class is described. A state-of-the-art LCF failure prediction method was used in a Monte Carlo simulation to generate a distribution of failure lives. A stochastic Stress/Life (S/N) model was used for materials characterization. The LCF failure model expresses fatigue life as a function of stochastic parameters including environmental parameters, loads, material properties, structural parameters, and model specification errors. The rationale for the particular characterization of each stochastic input parameter is described. The results and interpretation of the failure analysis are given.

Newlin, L.↗

NASA NTRS1990

Ply-level failure analysis of a graphite/epoxy laminate under bearing-bypass loading

A combined experimental and analytical study was conducted to investigate and predict the failure modes of a graphite/epoxy laminate subjected to combined bearing and bypass loading. Tests were conducted in a test machine that allowed the bearing-bypass load ratio to be controlled while a single-fastener coupon was loaded to failure in either tension or compression. Onset and ultimate failure modes and strengths were determined for each test case. The damage-onset modes were studied in detail by sectioning and micrographing the damaged specimens. A two-dimensional, finite-element analysis was conducted to determine lamina strains around the bolt hole. Damage onset consisted of matrix cracks, delamination, and fiber failures. Stiffness loss appeared to be caused by fiber failures rather than by matrix cracking and delamination. An unusual offset-compression mode was observed for compressive bearing-bypass loading in which the specimen failed across its width along a line offset from the hole. The computed lamina strains in the fiber direction were used in a combined analytical and experimental approach to predict bearing-bypass diagrams for damage onset from a few simple tests.

Naik, R. A.↗

NASA NTRS1990

Rocket engine failure detection using system identification techniques

The theoretical foundation and application of two univariate failure detection algorithms to Space Shuttle Main Engine (SSME) test firing data is presented. Both algorithms were applied to data collected during steady state operation of the engine. One algorithm, the time series algorithm, is based on time series techniques and involves the computation of autoregressive models. Time series techniques have been previously applied to SSME data. The second algorithm is based on standard signal processing techniques. It consists of tracking the variations in the average signal power with time. The average signal power algorithm is a newly proposed SSME failure detection algorithm. Seven nominal test firings were used to develop failure indication thresholds for each algorithm. These thresholds were tested using four anomalous firings and one additional nominal firing. Both algorithms provided significantly earlier failure indication times than did the current redline limit system. Neither algorithm gave false failure indications for the nominal firing. The strengths and weaknesses of the two algorithms are discussed and compared. The average signal algorithm was found to have several advantages over the time series algorithm.

Meyer, Claudia M.↗

NASA NTRS1990

Real-time failure control (SAFD)

The Real Time Failure Control program involves development of a failure detection algorithm, referred as System for Failure and Anomaly Detection (SAFD), for the Space Shuttle Main Engine (SSME). This failure detection approach is signal-based and it entails monitoring SSME measurement signals based on predetermined and computed mean values and standard deviations. Twenty four engine measurements are included in the algorithm and provisions are made to add more parameters if needed. Six major sections of research are presented: (1) SAFD algorithm development; (2) SAFD simulations; (3) Digital Transient Model failure simulation; (4) closed-loop simulation; (5) SAFD current limitations; and (6) enhancements planned for.

Panossian, Hagop V.↗

NASA NTRS1990

Failure detection and isolation experiments with the Langley Mini-Mast

A report is presented on experiments to demonstrate failure detection and isolation (FDI) using the flexible truss facility Mini-Mast at the NASA Langley Research Center. Two techniques are selected for study because they are applicable both to sensor and actuator failures and because they do not depend on hypotheses about the forms of possible failures. These two are the method of generalized parity relations and the failure detection filter. These methods utilize the concept of analytical redundancy and therefore their performance depends on the fidelity of the model of the dynamics of the system being monitored. Results are given for sensor FDI using generalized parity relations and input-output data collected during operation of the Mini-Mast. component failures are simulated in the data. The dependence of the performance of the methods on choices of the parameters in their implementation is explored.

Vander Velde, Wallace E.↗

NASA NTRS1991

Intelligent failure-tolerant control

An overview of failure-tolerant control is presented, focusing on the control of continuous-time dynamic systems (or plants) whose motions can be represented by integrals of nonlinear ordinary differential equations. Failure tolerance may be called upon to improve system reliability, maintainability, and survivability, and the issues attached to achieving these goals are examined. Robustness, which is required in some degree by all failure-tolerant systems, is discussed. The use of parallel redundancy is examined. Analytical redundancy, the principal functions of which are failure detection, failure identification, and control-system reconfiguration, is also considered. The use of expert systems and neural networks is discussed.

Stengel, Robert F.↗

NASA NTRS1990

Studies in knowledge-based diagnosis of failures in robotic assembly

The telerobot diagnostic system (TDS) is a knowledge-based system that is being developed for identification and diagnosis of failures in the space robotic domain. The system is able to isolate the symptoms of the failure, generate failure hypotheses based on these symptoms, and test their validity at various levels by interpreting or simulating the effects of the hypotheses on results of plan execution. The implementation of the TDS is outlined. The classification of failures and the types of system models used by the TDS are discussed. A detailed example of the TDS approach to failure diagnosis is provided.

Lam, Raymond K.↗

NASA NTRS1992

Failure detection and fault management techniques for flush airdata sensing systems

A high-angle-of-attack flush airdata sensing system was installed and flight tested on the F-18 High Alpha Research Vehicle at NASA-Dryden. This system uses a matrix of pressure orifices arranged in concentric circles on the nose of the vehicle to determine angles of attack, angles of sideslip, dynamic pressure, and static pressure as well as other airdata parameters. Results presented use an arrangement of 11 symmetrically distributed ports on the aircraft nose. Experience with this sensing system data indicates that the primary concern for real-time implementation is the detection and management of overall system and individual pressure sensor failures. The multiple port sensing system is more tolerant to small disturbances in the measured pressure data than conventional probe-based intrusive airdata systems. However, under adverse circumstances, large undetected failures in individual pressure ports can result in algorithm divergence and catastrophic failure of the entire system. How system and individual port failures may be detected using chi sq. analysis is shown. Once identified, the effects of failures are eliminated using weighted least squares.

Whitmore, Stephen A.↗

NASA NTRS1992

Compression failure mechanisms of uni-ply composite plates with a circular cutout

The effect of circular-hole size on the failure mode of uniply graphite-epoxy composite plates is investigated experimentally and analytically for uniaxial compressive loading. The test specimens are sandwiched between polyetherimide plastic for nondestructive evaluations of the uniply failure mechanisms associated with a range of hole sizes. Finite-element modeling based on classical lamination theory is conducted for the corresponding materials and geometries to reproduce the experimental results analytically. The type of compressive failure is found to be a function of hole size, with fiber buckling/kinking at the hole being the dominant failure mechanism for hole diam/plate width ratios exceeding 0.062. The results of the finite-element analysis supported the experimental data for these failure mechanisms and for those corresponding to smaller hole sizes.

Khamseh, A. R.↗

NASA NTRS1992

A micromechanics-based progressive failure model for laminated composite structures

A micromechanics-based mechanistic model for progressive failure analysis of laminated composite shell structures is developed. A finite-element program for laminated shell analysis is coupled with a micromechanical elasticity solution for predicting failure and effective composite properties. The laminate model is based on a third-order shell theory which allows for both transverse normal and shearing deformations. Results are presented for the progressive failure of a (0/90(4)s graphite/epoxy laminate under uniaxial tension. The effect of fiber volume fraction in the 90-deg plies on laminate behavior was studied, and it was found that decreasing the fiber-volume fraction in the off-axis plies did not affect the laminate stiffness or the ultimate failure load, but significantly increased the load at which initial failure occurred.

Averill, R. C.↗

NASA NTRS1993

Virtually-synchronous communication based on a weak failure suspector

Failure detectors (or, more accurately Failure Suspectors (FS)) appear to be a fundamental service upon which to build fault-tolerant, distributed applications. This paper shows that a FS with very weak semantics (i.e., that delivers failure and recovery information in no specific order) suffices to implement virtually-synchronous communication (VSC) in an asynchronous system subject to process crash failures and network partitions. The VSC paradigm is particularly useful in asynchronous systems and greatly simplifies building fault-tolerant applications that mask failures by replicating processes. We suggest a three-component architecture to implement virtually-synchronous communication: (1) at the lowest level, the FS component; (2) on top of it, a component (2a) that defines new views; and (3) a component (2b) that reliably multicasts messages within a view. The issues covered in this paper also lead to a better understanding of the various membership service semantics proposed in recent literature.

Schiper, Andre↗

NASA NTRS1993

Three-dimensional finite element progressive failure analysis of composite laminates under axial extension

A three-dimensional (3D) progressive failure algorithm is developed, where the layerwise laminate theory (LWLT) of Reddy is used for kinematic description. The finite element model based on the layerwise theory predicts both inplane and interlaminar stresses with the same accuracy as that of a conventional 3D finite element model and provides a convenient format for modeling the 3D stress fields in composite laminates. A parametric study is conducted to investigate the effect of out-of-plane material properties, 3D stiffness reduction methods, and boundary conditions on the failure loads and strains of a composite laminate under axial extension. The results indicate that different parameters have a different degree of influence on the failure loads and strains. The predictive ability of various phenomenological failure criteria is evaluated in the light of experimental results available in the literature, and the predictions of the LWLT are compared with those of the first-order shear deformation theory. It is concluded that a 3D stress analysis is necessary to predict accurately the failure behavior of composite laminates.

Reddy, Yeruva S.↗