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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 NTRS2010

Statistical and Probabilistic Extensions to Ground Operations' Discrete Event Simulation Modeling

NASA's human exploration initiatives will invest in technologies, public/private partnerships, and infrastructure, paving the way for the expansion of human civilization into the solar system and beyond. As it is has been for the past half century, the Kennedy Space Center will be the embarkation point for humankind's journey into the cosmos. Functioning as a next generation space launch complex, Kennedy's launch pads, integration facilities, processing areas, launch and recovery ranges will bustle with the activities of the world's space transportation providers. In developing this complex, KSC teams work through the potential operational scenarios: conducting trade studies, planning and budgeting for expensive and limited resources, and simulating alternative operational schemes. Numerous tools, among them discrete event simulation (DES), were matured during the Constellation Program to conduct such analyses with the purpose of optimizing the launch complex for maximum efficiency, safety, and flexibility while minimizing life cycle costs. Discrete event simulation is a computer-based modeling technique for complex and dynamic systems where the state of the system changes at discrete points in time and whose inputs may include random variables. DES is used to assess timelines and throughput, and to support operability studies and contingency analyses. It is applicable to any space launch campaign and informs decision-makers of the effects of varying numbers of expensive resources and the impact of off nominal scenarios on measures of performance. In order to develop representative DES models, methods were adopted, exploited, or created to extend traditional uses of DES. The Delphi method was adopted and utilized for task duration estimation. DES software was exploited for probabilistic event variation. A roll-up process was used, which was developed to reuse models and model elements in other less - detailed models. The DES team continues to innovate and expand DES capabilities to address KSC's planning needs.

Trocine, Linda↗

NASA NTRS1992

Space transportation architecture: Reliability sensitivities

A sensitivity analysis is given of the benefits and drawbacks associated with a proposed Earth to orbit vehicle architecture. The architecture represents a fleet of six vehicles (two existing, four proposed) that would be responsible for performing various missions as mandated by NASA and the U.S. Air Force. Each vehicle has a prescribed flight rate per year for a period of 31 years. By exposing this fleet of vehicles to a probabilistic environment where the fleet experiences failures, downtimes, setbacks, etc., the analysis involves determining the resiliency and costs associated with the fleet of specific vehicle/subsystem reliabilities. The resources required were actual observed data on the failures and downtimes associated with existing vehicles, data based on engineering judgement for proposed vehicles, and the development of a sensitivity analysis program.

Williams, A. M.↗

NASA NTRS2011

Assessing the Likelihood of Rare Medical Events in Astronauts

Despite over half a century of manned space flight, the space flight community is only now coming to fully assess the short and long term medical dangers of exposure to reduced gravity environments. Further, as new manned spacecraft are designed and with the advent of commercial flight capabilities to the general public, a full understanding of medical risk becomes even more critical for maintaining and understanding mission safety and crew health. To address these critical issues, the National Aeronautics and Space Administration (NASA) Human Research Program (HRP) has begun to address the medical hazards with a formalized risk management approach by effectively identifying and attempting to mitigate acute and chronic medical risks to manned space flight. This paper describes NASA Glenn Research Center?s (GRC) efforts to develop a systematic methodology to assess the likelihood of in-flight medical conditions. Using a probabilistic approach, medical risks are assessed using well established and accepted biomedical and human performance models in combination with fundamentally observed data that defines the astronauts? physical conditions, environment and activity levels. Two different examples of space flight risk are used to show the versatility of our approach and how it successfully integrates disparate information to provide HRP decision makers with a valuable source of information which is otherwise lacking.

Myers, Jerry G., Jr.↗

NASA NTRS2015

Dynamic Modeling of Ascent Abort Scenarios for Crewed Launches

For the last 30 years, the United States's human space program has been focused on low Earth orbit exploration and operations with the Space Shuttle and International Space Station programs. After nearly 50 years, the U.S. is again working to return humans beyond Earth orbit. To do so, NASA is developing a new launch vehicle and spacecraft to provide this capability. The launch vehicle is referred to as the Space Launch System (SLS) and the spacecraft is called Orion. The new launch system is being developed with an abort system that will enable the crew to escape launch failures that would otherwise be catastrophic as well as probabilistic design requirements set for probability of loss of crew (LOC) and loss of mission (LOM). In order to optimize the risk associated with designing this new launch system, as well as verifying the associated requirements, NASA has developed a comprehensive Probabilistic Risk Assessment (PRA) of the integrated ascent phase of the mission that includes the launch vehicle, spacecraft and ground launch facilities. Given the dynamic nature of rocket launches and the potential for things to go wrong, developing a PRA to assess the risk can be a very challenging effort. Prior to launch and after the crew has boarded the spacecraft, the risk exposure time can be on the order of three hours. During this time, events may initiate from either of the spacecraft, the launch vehicle, or the ground systems, thus requiring an emergency egress from the spacecraft to a safe ground location or a pad abort via the spacecraft's launch abort system. Following launch, again either the spacecraft or the launch vehicle can initiate the need for the crew to abort the mission and return to the home. Obviously, there are thousands of scenarios whose outcome depends on when the abort is initiated during ascent as to how the abort is performed. This includes modeling the risk associated with explosions and benign system failures that require aborting a spacecraft under very dynamic conditions, particularly in the lower atmosphere, and returning the crew home safely. This paper will provide an overview of the PRA model that has been developed of this new launch system, including some of the challenges that are associated with this effort. Key Words: PRA, space launches, human space program, ascent abort, spacecraft, launch vehicles

Bigler, Mark↗

NASA NTRS1991

Composite load spectra for select space propulsion structural components

The objective of this program is to develop generic load models with multiple levels of progressive sophistication to simulate the composite (combined) load spectra that are induced in space propulsion system components, representative of Space Shuttle Main Engines (SSME), such as transfer ducts, turbine blades, and liquid oxygen posts and system ducting. The first approach will consist of using state of the art probabilistic methods to describe the individual loading conditions and combinations of these loading conditions to synthesize the composite load spectra simulation. The second approach will consist of developing coupled models for composite load spectra simulation which combine the deterministic models for composite load dynamic, acoustic, high pressure, and high rotational speed, etc., load simulation using statistically varying coefficients. These coefficients will then be determined using advanced probabilistic simulation methods with and without strategically selected experimental data.

Newell, J. F.↗

NASA NTRS1989

An approximate methods approach to probabilistic structural analysis

A probabilistic structural analysis method (PSAM) is described which makes an approximate calculation of the structural response of a system, including the associated probabilistic distributions, with minimal computation time and cost, based on a simplified representation of the geometry, loads, and material. The method employs the fast probability integration (FPI) algorithm of Wu and Wirsching. Typical solution strategies are illustrated by formulations for a representative critical component chosen from the Space Shuttle Main Engine (SSME) as part of a major NASA-sponsored program on PSAM. Typical results are presented to demonstrate the role of the methodology in engineering design and analysis.

Mcclung, R. C.↗

NASA NTRS2002

System Level Uncertainty Assessment for Collaborative RLV Design

A collaborative design process utilizing Probabilistic Data Assessment (PDA) is showcased. Given the limitation of financial resources by both the government and industry, strategic decision makers need more than just traditional point designs, they need to be aware of the likelihood of these future designs to meet their objectives. This uncertainty, an ever-present character in the design process, can be embraced through a probabilistic design environment. A conceptual design process is presented that encapsulates the major engineering disciplines for a Third Generation Reusable Launch Vehicle (RLV). Toolsets consist of aerospace industry standard tools in disciplines such as trajectory, propulsion, mass properties, cost, operations, safety, and economics. Variations of the design process are presented that use different fidelities of tools. The disciplinary engineering models are used in a collaborative engineering framework utilizing Phoenix Integration's ModelCenter and AnalysisServer environment. These tools allow the designer to join disparate models and simulations together in a unified environment wherein each discipline can interact with any other discipline. The design process also uses probabilistic methods to generate the system level output metrics of interest for a RLV conceptual design. The specific system being examined is the Advanced Concept Rocket Engine 92 (ACRE-92) RLV. Previous experience and knowledge (in terms of input uncertainty distributions from experts and modeling and simulation codes) can be coupled with Monte Carlo processes to best predict the chances of program success.

Charania, A. C.↗

NASA NTRS1984

Optimal maintenance center inventories for fault-tolerant repairable systems

A probabilistic approach is taken to determine the optimal repairable parts inventory for a maintenance center, servicing machines which contain several m-out-of-n systems of different parts, with a constraint on the total inventory investment. A model, based on the discrete Markov process, accounts for a typical ultrareliable avionics system, such as one presently being developed by NASA. The dynamic programming algorithm for minimizing the stockout and holding costs is applied to an exemplary maintenance center, and solutions for single-item and multi-item cases are given. The computational burden is noted to be reasonable and a computer program is used to generate optimal solutions.

Lawrence, S. H.↗

NASA NTRS1990

Computational methods for probability of instability calculations

This paper summarizes the development of the methods and a computer program to compute the probability of instability of a dynamic system than can be represented by a system of second-order ordinary linear differential equations. Two instability criteria based upon the roots of the characteristics equation or Routh-Hurwitz test functions are investigated. Computational methods based on system reliability analysis methods and importance sampling concepts are proposed to perform efficient probabilistic analysis. Numerical examples are provided to demonstrate the methods.

Wu, Y.-T.↗

NASA NTRS1997

Multi-Disciplinary System Reliability Analysis

The objective of this study is to develop a new methodology for estimating the reliability of engineering systems that encompass multiple disciplines. The methodology is formulated in the context of the NESSUS probabilistic structural analysis code developed under the leadership of NASA Lewis Research Center. The NESSUS code has been successfully applied to the reliability estimation of a variety of structural engineering systems. This study examines whether the features of NESSUS could be used to investigate the reliability of systems in other disciplines such as heat transfer, fluid mechanics, electrical circuits etc., without considerable programming effort specific to each discipline. In this study, the mechanical equivalence between system behavior models in different disciplines are investigated to achieve this objective. A new methodology is presented for the analysis of heat transfer, fluid flow, and electrical circuit problems using the structural analysis routines within NESSUS, by utilizing the equivalence between the computational quantities in different disciplines. This technique is integrated with the fast probability integration and system reliability techniques within the NESSUS code, to successfully compute the system reliability of multi-disciplinary systems. Traditional as well as progressive failure analysis methods for system reliability estimation are demonstrated, through a numerical example of a heat exchanger system involving failure modes in structural, heat transfer and fluid flow disciplines.

Mahadevan, Sankaran↗

NASA NTRS2001

Multidisciplinary System Reliability Analysis

The objective of this study is to develop a new methodology for estimating the reliability of engineering systems that encompass multiple disciplines. The methodology is formulated in the context of the NESSUS probabilistic structural analysis code, developed under the leadership of NASA Glenn Research Center. The NESSUS code has been successfully applied to the reliability estimation of a variety of structural engineering systems. This study examines whether the features of NESSUS could be used to investigate the reliability of systems in other disciplines such as heat transfer, fluid mechanics, electrical circuits etc., without considerable programming effort specific to each discipline. In this study, the mechanical equivalence between system behavior models in different disciplines are investigated to achieve this objective. A new methodology is presented for the analysis of heat transfer, fluid flow, and electrical circuit problems using the structural analysis routines within NESSUS, by utilizing the equivalence between the computational quantities in different disciplines. This technique is integrated with the fast probability integration and system reliability techniques within the NESSUS code, to successfully compute the system reliability of multidisciplinary systems. Traditional as well as progressive failure analysis methods for system reliability estimation are demonstrated, through a numerical example of a heat exchanger system involving failure modes in structural, heat transfer and fluid flow disciplines.

Mahadevan, Sankaran↗

NASA NTRS2003

Statistical Evaluation and Improvement of Methods for Combining Random and Harmonic Loads

Structures in many environments experience both random and harmonic excitation. A variety of closed-form techniques has been used in the aerospace industry to combine the loads resulting from the two sources. The resulting combined loads are then used to design for both yield/ultimate strength and high- cycle fatigue capability. This Technical Publication examines the cumulative distribution percentiles obtained using each method by integrating the joint probability density function of the sine and random components. A new Microsoft Excel spreadsheet macro that links with the software program Mathematica to calculate the combined value corresponding to any desired percentile is then presented along with a curve tit to this value. Another Excel macro that calculates the combination using Monte Carlo simulation is shown. Unlike the traditional techniques. these methods quantify the calculated load value with a consistent percentile. Using either of the presented methods can be extremely valuable in probabilistic design, which requires a statistical characterization of the loading. Additionally, since the CDF at high probability levels is very flat, the design value is extremely sensitive to the predetermined percentile; therefore, applying the new techniques can substantially lower the design loading without losing any of the identified structural reliability.

Brown, A. M.↗

NASA NTRS2005

Uncertainty Considerations for Ballistic Limit Equations

The overall risk for any spacecraft system is typically determined using a Probabilistic Risk Assessment (PRA). A PRA attempts to determine the overall risk associated with a particular mission by factoring in all known risks (and their corresponding uncertainties, if known) to the spacecraft during its mission. The threat to mission and human life posed by the mircro-meteoroid & orbital debris (MMOD) environment is one of the risks. NASA uses the BUMPER II program to provide point estimate predictions of MMOD risk for the Space Shuttle and the International Space Station. However, BUMPER II does not provide uncertainty bounds or confidence intervals for its predictions. With so many uncertainties believed to be present in the models used within BUMPER II, providing uncertainty bounds with BUMPER II results would appear to be essential to properly evaluating its predictions of MMOD risk. The uncertainties in BUMPER II come primarily from three areas: damage prediction/ballistic limit equations, environment models, and failure criteria definitions. In order to quantify the overall uncertainty bounds on MMOD risk predictions, the uncertainties in these three areas must be identified. In this paper, possible approaches through which uncertainty bounds can be developed for the various damage prediction and ballistic limit equations encoded within the shuttle and station versions of BUMPER II are presented and discussed. We begin the paper with a review of the current approaches used by NASA to perform a PRA for the Space Shuttle and the International Space Station, followed by a review of the results of a recent sensitivity analysis performed by NASA using the shuttle version of the BUMPER II code. Following a discussion of the various equations that are encoded in BUMPER II, we propose several possible approaches for establishing uncertainty bounds for the equations within BUMPER II. We conclude with an evaluation of these approaches and present a recommendation regarding which of them would be the most appropriate to follow.

Schonberg, W. P.↗

NASA NTRS2004

Statistical Comparison and Improvement of Methods for Combining Random and Harmonic Loads

Structures in many environments experience both random and harmonic excitation. A variety of closed-form techniques has been used in the aerospace industry to combine the loads resulting from the two sources. The resulting combined loads are then used to design for both yield ultimate strength and high cycle fatigue capability. This paper examines the cumulative distribution function (CDF) percentiles obtained using each method by integrating the joint probability density function of the sine and random components. A new Microsoft Excel spreadsheet macro that links with the software program Mathematics is then used to calculate the combined value corresponding to any desired percentile along with a curve fit to this value. Another Excel macro is used to calculate the combination using a Monte Carlo simulation. Unlike the traditional techniques, these methods quantify the calculated load value with a Consistent percentile. Using either of the presented methods can be extremely valuable in probabilistic design, which requires a statistical characterization of the loading. Also, since the CDF at high probability levels is very flat, the design value is extremely sensitive to the predetermined percentile; therefore, applying the new techniques can lower the design loading substantially without losing any of the identified structural reliability.

Brown, Andrew M.↗

NASA NTRS1973

Space shuttle solid rocket booster recovery system definition. Volume 2: SRB water impact Monte Carlo computer program, user's manual

The HD 220 program was created as part of the space shuttle solid rocket booster recovery system definition. The model was generated to investigate the damage to SRB components under water impact loads. The random nature of environmental parameters, such as ocean waves and wind conditions, necessitates estimation of the relative frequency of occurrence for these parameters. The nondeterministic nature of component strengths also lends itself to probabilistic simulation. The Monte Carlo technique allows the simultaneous perturbation of multiple independent parameters and provides outputs describing the probability distribution functions of the dependent parameters. This allows the user to determine the required statistics for each output parameter.

Source record↗

NASA NTRS2018

Determination of Uncertainties for Analytically Derived Material Properties to Be Used in Monte Carlo Based Orion Heatshield Sizing

Ablative materials are often used for spacecraft heatshields to protect underlying structures from the extreme environments associated with atmospheric reentry. NASA's Orion EM-1 capsule has been designed to use a molded Avcoat material system. In order to determine the required heatshield thickness, a Monte Carlo approach to the sizing process was proposed. To perform the Monte Carlo simulation, statistical uncertainties on all material property input parameters were required. Obtaining these values for measured properties is straightforward, however input parameters that are derived analytically have historically used uncertainties based on engineering judgment. A MATLAB program was created to use laboratory generated thermogravimetric analysis (TGA) data to calculate uncertainties on the Arrhenius parameters for molded Avcoat. Uncertainties associated with the normalized ablation rate and pyrolysis gas enthalpy were also generated using a wrapper script and the ACE code. These uncertainties could then be tied directly to measured values of individual elemental constituents. The resulting uncertainty values will allow for a probabilistic sizing approach on molded Avcoat with a higher level of confidence in the input parameters.

material property uncertainties↗

NASA NTRS2008

Structural Benchmark Creep Testing for the Advanced Stirling Convertor Heater Head

The National Aeronautics and Space Administration (NASA) has identified the high efficiency Advanced Stirling Radioisotope Generator (ASRG) as a candidate power source for use on long duration Science missions such as lunar applications, Mars rovers, and deep space missions. For the inherent long life times required, a structurally significant design limit for the heater head component of the ASRG Advanced Stirling Convertor (ASC) is creep deformation induced at low stress levels and high temperatures. Demonstrating proof of adequate margins on creep deformation and rupture for the operating conditions and the MarM-247 material of construction is a challenge that the NASA Glenn Research Center is addressing. The combined analytical and experimental program ensures integrity and high reliability of the heater head for its 17-year design life. The life assessment approach starts with an extensive series of uniaxial creep tests on thin MarM-247 specimens that comprise the same chemistry, microstructure, and heat treatment processing as the heater head itself. This effort addresses a scarcity of openly available creep properties for the material as well as for the virtual absence of understanding of the effect on creep properties due to very thin walls, fine grains, low stress levels, and high-temperature fabrication steps. The approach continues with a considerable analytical effort, both deterministically to evaluate the median creep life using nonlinear finite element analysis, and probabilistically to calculate the heater head s reliability to a higher degree. Finally, the approach includes a substantial structural benchmark creep testing activity to calibrate and validate the analytical work. This last element provides high fidelity testing of prototypical heater head test articles; the testing includes the relevant material issues and the essential multiaxial stress state, and applies prototypical and accelerated temperature profiles for timely results in a highly controlled laboratory environment. This paper focuses on the last element and presents a preliminary methodology for creep rate prediction, the experimental methods, test challenges, and results from benchmark testing of a trial MarM-247 heater head test article. The results compare favorably with the analytical strain predictions. A description of other test findings is provided, and recommendations for future test procedures are suggested. The manuscript concludes with describing the potential impact of the heater head creep life assessment and benchmark testing effort on the ASC program.

Krause, David L.↗