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Reliability analysis in the Office of Safety, Environmental, and Mission Assurance (OSEMA)

The technical personnel in the SEMA office are working to provide the highest degree of value-added activities to their support of the NASA Langley Research Center mission. Management perceives that reliability analysis tools and an understanding of a comprehensive systems approach to reliability will be a foundation of this change process. Since the office is involved in a broad range of activities supporting space mission projects and operating activities (such as wind tunnels and facilities), it was not clear what reliability tools the office should be familiar with and how these tools could serve as a flexible knowledge base for organizational growth. Interviews and discussions with the office personnel (both technicians and engineers) revealed that job responsibilities ranged from incoming inspection to component or system analysis to safety and risk. It was apparent that a broad base in applied probability and reliability along with tools for practical application was required by the office. A series of ten class sessions with a duration of two hours each was organized and scheduled. Hand-out materials were developed and practical examples based on the type of work performed by the office personnel were included. Topics covered were: Reliability Systems - a broad system oriented approach to reliability; Probability Distributions - discrete and continuous distributions; Sampling and Confidence Intervals - random sampling and sampling plans; Data Analysis and Estimation - Model selection and parameter estimates; and Reliability Tools - block diagrams, fault trees, event trees, FMEA. In the future, this information will be used to review and assess existing equipment and processes from a reliability system perspective. An analysis of incoming materials sampling plans was also completed. This study looked at the issues associated with Mil Std 105 and changes for a zero defect acceptance sampling plan.

Kauffmann, Paul J.

Reliability Analysis of Complex NASA Systems with Model-Based Engineering

The emergence of model-based engineering, with Model- Based Systems Engineering (MBSE) leading the way, is transforming design and analysis methodologies. The recognized benefits to systems development include moving from document-centric information systems and document-centric project communication to a model-centric environment in which control of design changes in the life cycles is facilitated. In addition, a “single source of truth” about the system, that is up-to-date in all respects of the design, becomes the authoritative source of data and information about the system. This promotes consistency and efficiency in regard to integration of the system elements as the design emerges and thereby may further optimize the design. Therefore Reliability Engineers (REs) supporting NASA missions must be integrated into model-based engineering to ensure the outputs of their analyses are relevant and value-needed to the design, development, and operational processes for failure risks assessment and communication.

FMEA/FMECA

Reliability Analysis of Complex NASA Systems with Model Based Engineering

The emergence of model-based engineering, with Model- Based Systems Engineering (MBSE) leading the way, is transforming design and analysis methodologies. The recognized benefits to systems development include moving from document-centric information systems and document-centric project communication to a model-centric environment in which control of design changes in the life cycles is facilitated. In addition, a “single source of truth” about the system, that is up-to-date in all respects of the design, becomes the authoritative source of data and information about the system. This promotes consistency and efficiency in regard to integration of the system elements as the design emerges and thereby may further optimize the design. Therefore Reliability Engineers (REs) supporting NASA missions must be integrated into model-based engineering to ensure the outputs of their analyses are relevant and value-needed to the design, development, and operational processes for failure risks assessment and communication.

Reliability prediction

Reliability model generator specification

The Reliability Model Generator (RMG), a program which produces reliability models from block diagrams for ASSIST, the interface for the reliability evaluation tool SURE is described. An account is given of motivation for RMG and the implemented algorithms are discussed. The appendices contain the algorithms and two detailed traces of examples.

Cohen, Gerald C.

Reliability Practice at NASA Goddard Space Flight Center

This paper describes in brief the Reliability and Maintainability (R&M) Programs performed directly by the reliability branch at Goddard Space Flight Center (GSFC). The mission assurance requirements flow down is explained. GSFC practices for PRA, reliability prediction/fault tree analysis/reliability block diagram, FMEA, part stress and derating analysis, worst case analysis, trend analysis, limit life items are presented. Lessons learned are summarized and recommendations on improvement are identified.

Pruessner, Paula S.

Hazards Analysis and Failure Modes and Effects Criticality Analysis (FMECA) of Four Concept Vehicle Propulsion Systems

The primary objective of this research effort is to identify failure modes and hazards associated with the concept vehicles and to perform functional hazard analyses (FHA) and failure modes and effects criticality analyses (FMECA) for each. Boeing also created a Fault Tree Analysis (FTA) for each of the concept vehicles, as the FTA contains the connectivity between systems and is an accepted, top-down method to analyze the safety of an air-vehicle. Conceptual design of notional powertrain configuration for each of four (4) NASA RVLT (Revolutionary Vertical Lift Technology) Concept Vehicles were developed in as much detail as was necessary to support the reliability and safety analysis for this project. Functional block diagrams from each of the conceptual powertrain configurations were created and used to order the FHA, FMECA, and FTA. Hazards were identified and the severity of each were categorized in the FHA for use in a follow-up FMECA. The FTA took inputs from the FMECA and the functional block diagrams to develop the connectivity and develop a quantitative architecture that could be used to perform sensitivity studies, as related to vehicle safety.Guidelines for reliability targets for both the air vehicle and the operation in the UAM (Urban Air Mobility) mission are discussed. An industry literature search was performed in order to assess gaps in existing government regulations and industry specifications. The industry literature search led to air-vehicle and operational reliability discussions, as related to Distributed Electric/Hybrid-Electric Propulsion (DE/HEP) system operating in the UAM role. A discussion of results and recommendations for future work is also provided.

Hazards Analysis

Advanced techniques in reliability model representation and solution

The current tendency of flight control system designs is towards increased integration of applications and increased distribution of computational elements. The reliability analysis of such systems is difficult because subsystem interactions are increasingly interdependent. Researchers at NASA Langley Research Center have been working for several years to extend the capability of Markov modeling techniques to address these problems. This effort has been focused in the areas of increased model abstraction and increased computational capability. The reliability model generator (RMG) is a software tool that uses as input a graphical object-oriented block diagram of the system. RMG uses a failure-effects algorithm to produce the reliability model from the graphical description. The ASSURE software tool is a parallel processing program that uses the semi-Markov unreliability range evaluator (SURE) solution technique and the abstract semi-Markov specification interface to the SURE tool (ASSIST) modeling language. A failure modes-effects simulation is used by ASSURE. These tools were used to analyze a significant portion of a complex flight control system. The successful combination of the power of graphical representation, automated model generation, and parallel computation leads to the conclusion that distributed fault-tolerant system architectures can now be analyzed.

Palumbo, Daniel L.

Structural dynamics: Probabilistic structural analysis methods. Program overview

A brief description is provided of the fundamental aspects of a quantification process. Progress since the last structural durability conference in 1989 is summarized. The methodology to date and that to be developed during the life of the program is presented. The uncertain factors are presented. The approach is outlined that is required to achieve component and/or system certification in the shortest possible time for affordable reliability risk. Two new elements appear in a block diagram: (1) uncertainties in human factor, and (2) uncertainties in the computer code. Research to quantify the uncertainties in the human factor was initiated and is discussed.

Chamis, Christos C.

Generation and analysis of large reliability models

An effort has been underway for several years at NASA's Langley Research Center to extend the capability of Markov modeling techniques for reliability analysis to the designers of highly reliable avionic systems. This effort has been focused in the areas of increased model abstraction and increased computational capability. The reliability model generator (RMG), a software tool which uses as input a graphical, object-oriented block diagram of the system, is discussed. RMG uses an automated failure modes-effects analysis algorithm to produce the reliability model from the graphical description. Also considered is the ASSURE software tool, a parallel processing program which uses the ASSIST modeling language and SURE semi-Markov solution technique. An executable failure modes-effects analysis is used by ASSURE. The successful combination of the power of graphical representation, automated model generation, and parallel computation leads to the conclusion that large system architectures can now be analyzed.

Aerospace electronics

Neural network applications in telecommunications

Neural network capabilities include automatic and organized handling of complex information, quick adaptation to continuously changing environments, nonlinear modeling, and parallel implementation. This viewgraph presentation presents Bellcore work on applications, learning chip computational function, learning system block diagram, neural network equalization, broadband access control, calling-card fraud detection, software reliability prediction, and conclusions.

Alspector, Joshua

Development of the Functional Flow Block Diagram for the J-2X Rocket Engine System

The J-2X program calls for the upgrade of the Apollo-era Rocketdyne J-2 engine to higher power levels, using new materials and manufacturing techniques, and with more restrictive safety and reliability requirements than prior human-rated engines in NASA history. Such requirements demand a comprehensive systems engineering effort to ensure success. Pratt & Whitney Rocketdyne system engineers performed a functional analysis of the engine to establish the functional architecture. J-2X functions were captured in six major operational blocks. Each block was divided into sub-blocks or states. In each sub-block, functions necessary to perform each state were determined. A functional engine schematic consistent with the fidelity of the system model was defined for this analysis. The blocks, sub-blocks, and functions were sequentially numbered to differentiate the states in which the function were performed and to indicate the sequence of events. The Engine System was functionally partitioned, to provide separate and unique functional operators. Establishing unique functional operators as work output of the System Architecture process is novel in Liquid Propulsion Engine design. Each functional operator was described such that its unique functionality was identified. The decomposed functions were then allocated to the functional operators both of which were the inputs to the subsystem or component performance specifications. PWR also used a novel approach to identify and map the engine functional requirements to customer-specified functions. The final result was a comprehensive Functional Flow Block Diagram (FFBD) for the J-2X Engine System, decomposed to the component level and mapped to all functional requirements. This FFBD greatly facilitates component specification development, providing a well-defined trade space for functional trades at the subsystem and component level. It also provides a framework for function-based failure modes and effects analysis (FMEA), and a rigorous baseline for the functional architecture.

White, Thomas

Design and sparing techniques to meet specified performance life

Specified performance life technique starts with the general description of what is wanted, defines in block diagram the operational needs, and then defines the functional systems required. The technique is similar to a truncated reliability model, but the calculation is simplified by use of a Poisson distribution approach to failure probability.

Holstead, A. J., Jr.

Apollo Telescope Mount (ATM) gimballed star tracker

Design and development of six gimballed star trackers for Skylab's Apollo Telescope Mount, which performed successfully on all three manned Skylab missions and accumulated a total usage time of approximately 3,500 hours, is described in terms of configurations, materials and construction, qualification testing, performance, and reliability characteristics. A brief program history and design changes incorporated during the life of the program are also discussed. Extensive drawings, block diagrams, and photographs are provided.

Lana, J. D.

High efficiency low cost monolithic module for SARSAT distress beacons

The program objectives were to develop a highly efficient, low cost RF module for SARSAT beacons; achieve significantly lower battery current drain, amount of heat generated, and size of battery required; utilize MMIC technology to improve efficiency, reliability, packaging, and cost; and provide a technology database for GaAs based UHF RF circuit architectures. Presented in viewgraph form are functional block diagrams of the SARSAT distress beacon and beacon RF module as well as performance goals, schematic diagrams, predicted performances, and measured performances for the phase modulator and power amplifier.

Petersen, Wendell C.

Event/Time/Availability/Reliability-Analysis Program

ETARA is interactive, menu-driven program that performs simulations for analysis of reliability, availability, and maintainability. Written to evaluate performance of electrical power system of Space Station Freedom, but methodology and software applied to any system represented by block diagram. Program written in IBM APL.

Viterna, L. A.

NASA Manufacturing and Test Requirements for Normally Closed Pyrovalves for Hazardous Flight Systems Applications

Pyrovalves (figure 1, Basic Pyrovalve Design and Features,) are typically lighter, more reliable, and in most cases less expensive than other types of valves. They also consume less electrical power. They are single-use devices that are used in propulsion systems to isolate propellants or pressurant gases. These fluids may be hazardous because of their toxicity, reactivity, temperature, or high pressure. Note that in the simplified block diagram below not all detail features are shown so that those of major interest are more prominent. The diagram is provided to point out the various features that are discussed in this Specification. Features of some NC parent metal valve designs may differ. In 2013, the NESC concluded an extensive study of the reliability and safety of NC parent metal valves used in payloads carried aboard ELVs. The assessment successfully evaluated technical data to determine the risk of NC parent metal valve leakage or inadvertent activation in ELV payloads. The study resulted in numerous recommendations to ensure personnel and hardware/facility safety during ground processing of ELV payloads. One of those recommendations was to establish a NASA specification for NC parent metal valves. This Specification is a result of that recommendation, which is documented in NESC-RP-10-00614.

McDougle, Stephen H.

Experience gained from computer processing of physical experimental data during the restoration of measured values

The processing stage in which the restored values of the physical parameters are received is described. The following main steps are discussed: estimation of the state of the telemetry data, processing of the calibration data, and determination of the errors in the data; data decommutation and analysis of the structure of measurement cycles for each instrument; decoding, estimates of the reliability of the restored data, and their agreement with the models adopted for the measurement process; and analysis of errors due to deterministic and random factors. A block diagram of the method is presented.

Mamotko, Z. N.

Modeling, simulation and control for a cryogenic fluid management facility, preliminary report

The synthesis of a control system for a cryogenic fluid management facility was studied. The severe demand for reliability as well as instrumentation and control unique to the Space Station environment are prime considerations. Realizing that the effective control system depends heavily on quantitative description of the facility dynamics, a methodology for process identification and parameter estimation is postulated. A block diagram of the associated control system is also produced. Finally, an on-line adaptive control strategy is developed utilizing optimization of the velocity form control parameters (proportional gains, integration and derivative time constants) in appropriate difference equations for direct digital control. Of special concern are the communications, software and hardware supporting interaction between the ground and orbital systems. It is visualized that specialist in the OSI/ISO utilizing the Ada programming language will influence further development, testing and validation of the simplistic models presented here for adaptation to the actual flight environment.

Turner, Max A.