Humanlike Robots as Artificial Inspectors: The Science Fiction and Engineering Reality
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Bar-Cohen, Yoseph↗
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Humanlike Robots as Artificial Inspectors: The Science Fiction and Engineering Reality
No abstract provided
Bar-Cohen, Yoseph↗
NASA NDE Fracture Critical Detectable Flaw Sizes History and Methodology
NASA requires that NDE methods and inspectors demonstrate 90% Probability of Detection (POD) with 95% confidence for critical flaw sizes when inspecting fracture critical metallic components. NASA addresses the known variability of NDE inspector capability in two ways. The first, Special NDE, requires that every inspector demonstrate the required 90/95 POD, which is resource intensive. The second approach is Standard NDE for which conservative flaw sizes for different NDE methods are provided such that it is expected that most properly trained inspectors will exceed the 90/95 POD requirement. As such, individual POD demonstration testing is not required. The origin of NASA Standard NDE dates to the start of the Space Shuttle Program in the early 1970’s. In the first study to quantitatively assess NDE methods and inspectors, the performance of multiple inspectors was evaluated for different NDE methods using a large set of fatigue cracked specimens. A rudimentary POD analysis was performed to estimate the 90/95 POD flaw size for each inspector for each method. Additionally, the average and standard deviation of the 90/95 POD flaw size across the multiple inspectors was calculated to estimate the flaw size for which 95 percent of inspectors would provide the 90/95 POD capability. These estimated 90/95/95 POD flaw sizes evolved into the NASA Standard NDE flaw sizes still in use for structural analysis five decades later. The methodology for performing Standard NDE POD studies was never documented in NASA requirements. Furthermore, POD analysis methods have significantly evolved since this seminal study. Likewise, NDE methods have improved and there has been a push to reassess Standard NDE flaw sizes for existing methods, and to develop Standard NDE flaw sizes for new methods such as digital radiography. In this study, a Standard NDE POD methodology was developed and baselined using the historical data. This reanalysis of the historical data identified several deficiencies in the original test plan as well as an overall lack of conservatism in the estimated 90/95/95 POD flaw sizes. The results of this historical review and the new methodology are being incorporated into an update of NASA NDE POD requirements.
Nondestructive Evaluation↗
3D X-Ray Luggage-Screening System
A three-dimensional (3D) x-ray luggage- screening system has been proposed to reduce the fatigue experienced by human inspectors and increase their ability to detect weapons and other contraband. The system and variants thereof could supplant thousands of xray scanners now in use at hundreds of airports in the United States and other countries. The device would be applicable to any security checkpoint application where current two-dimensional scanners are in use. A conventional x-ray luggage scanner generates a single two-dimensional (2D) image that conveys no depth information. Therefore, a human inspector must scrutinize the image in an effort to understand ambiguous-appearing objects as they pass by at high speed on a conveyor belt. Such a high level of concentration can induce fatigue, causing the inspector to reduce concentration and vigilance. In addition, because of the lack of depth information, contraband objects could be made more difficult to detect by positioning them near other objects so as to create x-ray images that confuse inspectors. The proposed system would make it unnecessary for a human inspector to interpret 2D images, which show objects at different depths as superimposed. Instead, the system would take advantage of the natural human ability to infer 3D information from stereographic or stereoscopic images. The inspector would be able to perceive two objects at different depths, in a more nearly natural manner, as distinct 3D objects lying at different depths. Hence, the inspector could recognize objects with greater accuracy and less effort. The major components of the proposed system would be similar to those of x-ray luggage scanners now in use. As in a conventional x-ray scanner, there would be an x-ray source. Unlike in a conventional scanner, there would be two x-ray image sensors, denoted the left and right sensors, located at positions along the conveyor that are upstream and downstream, respectively (see figure). X-ray illumination may be provided by a single source or by two sources. The position of the conveyor would be detected to provide a means of matching the appropriate left- and right-eye images of an item under inspection. The appropriate right- and left-eye images of an item would be displayed simultaneously to the right and left eyes, respectively, of the human inspector, using commercially available stereo display screens. The human operator could adjust viewing parameters for maximum viewing comfort. The stereographic images thus generated would differ from true stereoscopic images by small distortions that are characteristic of radiographic images in general, but these distortions would not diminish the value of the images for identifying distinct objects at different depths.
Fernandez, Kenneth↗
Inspection In Overhead Spaces Containing Asbestos
Procedure for inspection in spaces above dropped ceilings that contain asbestos saves time and effort without sacrificing safety. With new method, only items of safety equipment needed are glove bag, storage bag, and roll of adhesive tape. Inspector tapes glove bag tightly to support grid around ceiling tile to be removed. With hands in gloves inspector lifts tile gently and places it aside. Extending head and shoulders into bag, inspector examines space above ceiling with help of flashlight.
Bell, Jacque↗
The NASA competitive placement plan for positions GS-15 and below (including trades and labor positions)
This plan provides the framework for selection based on merit from among the best qualified candidates available. Selections will be made without regard to political, religious, or labor organization affiliation or nonaffiliation, marital status, race, color, sex, national origin, nondisqualifying disability, or age. This plan does not guarantee promotion but rather ensures that all qualified available candidates receive fair and equitable consideration for positions filled under these competitive procedures. Announcing a vacancy under this plan is only one method of locating applicants for a position and can be used in conjunction with other methods. Subject to applicable law and regulation, selection of an individual to fill a position is the decision of management, as is the decision as to the method(s) to be used in identifying candidates. This plan is applicable to all NASA Installations. It covers all positions in the competitive service at (and below) the GS/GM-15 level (including all trades and labor positions), except positions in the Office of the Inspector General. The requirements herein are not intended to, nor should they be construed to limit in any way, the independent personnel authority of the Inspector General under the Inspector General Act, as Amended.
Source record↗
Static measurement of the thickness of the ablative coating of the solid rocket boosters
The Solid Rocket Boosters (SRB's) used to launch the Space Shuttle are coated with a layer of ablative material to prevent thermal damage when they reenter the earth's atmosphere. The coating consists of a mixture of cork, glass, and resin. A new coating (Marshall Convergent Coating, MCC-2) was recently developed that is environmentally complaint. The coating must meet certain minimum thickness standards in order to protect the SRB. The coating is applied by a robot controlled nozzle that moves from the bottom to top, as the rocket part rotates on a table. Several coats are applied, building up to the desired thickness. Inspectors do a limited amount of destructive 'wet' testing. This involves an inspector inserting a rod in the wet coating and removing the rod. This results in a hole that, of course, must be patched later. The material is cured and the thickness is measured. There is no real-time feedback as the coating is being applied. Although this might seem like the best way to control thickness, the problems with 'blowback' (reflected material covering the sensor) are formidable, and have not been solved. After the thermal coating is applied, a protective top coat is applied. The SRB part is then placed in a oven and baked to harden the surface. The operations personnel then measure the thickness of the layer using the Kaman 7200 Displacement Measuring System. The probe is placed on the surface. One person (the inspector) reads the instrument, while another(the technician) records the thickness. Measurements are taken at one foot intervals. After the measurements are taken, the number of low readings is tabulated. If more than 10 percent of the points fall below the minimum value, there is a design review, and the part may be stripped of coating, and a new coating is applied. There is no other analysis.
Harrison, Harry C.↗
Effect of Liquid Penetrant Sensitivity on Probability of Detection
The objective of the task is to investigate the effect of liquid penetrant sensitivity level on probability of detection (POD) of cracks in various metals. NASA-STD-5009 currently requires the use of only sensitivity level 4 liquid penetrants for NASA Standard Level inspections. This requirement is based on the fact that the data used to establish the reliably detectable flaw sizes penetrant inspection was from studies performed in the 1970s using penetrant deemed to be equivalent only to modern day sensitivity level 4 penetrants. However, many NDE contractors supporting NASA Centers routinely use sensitivity level 3 penetrants. Because of the new NASA-STD-5009 requirement, these contractors will have to either shift to sensitivity level 4 penetrants or perform formal POD demonstration tests to qualify their existing process. We propose a study to compare the POD generated for two penetrant manufactures, Sherwin and Magnaflux, and for the two most common penetrant inspection methods, water washable and post emulsifiable, hydrophilic. NDE vendors local to GSFC will be employed. A total of six inspectors will inspect a set of crack panels with a broad range of fatigue crack sizes. Each inspector will perform eight inspections of the panel set using the combination of methods and sensitivity levels described above. At least one inspector will also perform multiple inspections using a fixed technique to investigate repeatability. The hit/miss data sets will be evaluated using both the NASA generated DOEPOD software and the MIL-STD-1823 software.
Parker, Bradford H.↗
Run-time parallelization and scheduling of loops
Run time methods are studied to automatically parallelize and schedule iterations of a do loop in certain cases, where compile-time information is inadequate. The methods presented involve execution time preprocessing of the loop. At compile-time, these methods set up the framework for performing a loop dependency analysis. At run time, wave fronts of concurrently executable loop iterations are identified. Using this wavefront information, loop iterations are reordered for increased parallelism. Symbolic transformation rules are used to produce: inspector procedures that perform execution time preprocessing and executors or transformed versions of source code loop structures. These transformed loop structures carry out the calculations planned in the inspector procedures. Performance results are presented from experiments conducted on the Encore Multimax. These results illustrate that run time reordering of loop indices can have a significant impact on performance. Furthermore, the overheads associated with this type of reordering are amortized when the loop is executed several times with the same dependency structure.
Saltz, Joel H.↗
Run-time parallelization and scheduling of loops
Run-time methods are studied to automatically parallelize and schedule iterations of a do loop in certain cases where compile-time information is inadequate. The methods presented involve execution time preprocessing of the loop. At compile-time, these methods set up the framework for performing a loop dependency analysis. At run-time, wavefronts of concurrently executable loop iterations are identified. Using this wavefront information, loop iterations are reordered for increased parallelism. Symbolic transformation rules are used to produce: inspector procedures that perform execution time preprocessing, and executors or transformed versions of source code loop structures. These transformed loop structures carry out the calculations planned in the inspector procedures. Performance results are presented from experiments conducted on the Encore Multimax. These results illustrate that run-time reordering of loop indexes can have a significant impact on performance.
Saltz, Joel H.↗
Voice-Recognition System Records Inspection Data
Main Injector Voice Activated Record (MIVAR) system acts on vocal commands and processes spoken inspection data into electronic and printed inspection reports. Devised to improve acquisition and recording of data from borescope inspections of interiors of liquid-oxygen-injecting tubes on main engine of Space Shuttle. With modifications, system used in other situations to relieve inspectors of manual recording of data. Enhances flow of work and quality of data acquired by enabling inspector to remain visually focused on workpiece.
Rochester, Larry L.↗
Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware
USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB. TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly, to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC/solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.
Novak, Howard L.↗
Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware
USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB (Solid Rocket Booster). TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly. to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC/solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.
Novak, Howard L.↗
Environmentally Compatible Vapor-Phase Corrosion Inhibitor for Space Shuttle Hardware
USA-SRB Element is responsible for the assembly and refurbishment of the non-motor components of the SRB as part of Space Shuttle. Thrust Vector Control (TVC) frames structurally support components of the TVC system located in the aft skirt of the SRB. TVC frames are exposed to the seacoast environment after refurbishment and, also, to seawater immersion after splashdown, and during tow-back to CCAFS-Hangar AF refurbishment facilities. During refurbishment operations it was found that numerous TVC frames were experiencing internal corrosion and coating failures, both from salt air and seawater intrusions. Inspectors using borescopes would visually examine the internal cavities of the complicated aluminum alloy welded tubular structure. It was very difficult for inspectors to examine cavity corners and tubing intersections and particularly, to determine the extent of the corrosion and coating anomalies. Physical access to TVC frame internal cavities for corrosion removal and coating repair was virtually impossible, and an improved method using a Liquid (water based) Vapor-phase Corrosion Inhibitor (LVCI) for preventing initiation of new corrosion, and mitigating and/or stopping existing corrosion growth was recommended in lieu of hazardous paint solvents and high VOC / solvent based corrosion inhibitors. In addition, the borescopic inspection method used to detect corrosion, and/or coating anomalies had severe limitations because of part geometry, and an improved non-destructive inspection (NDI) method using Neutron Radiography (N-Ray) was also recommended.
Novak, Howard L.↗
Tool for Inspecting Alignment of Twinaxial Connectors
A proposed tool would be used to inspect alignments of mating twinaxial-connector assemblies on interconnecting wiring harnesses. More specifically, the tool would be used to inspect the alignment of each contact pin of each connector on one assembly with the corresponding socket in the corresponding connector on the other assembly. It is necessary to inspect the alignment because if mating of the assemblies is attempted when any pin/socket pair is misaligned beyond tolerance, the connection will not be completed and the dielectric material in the socket will be damaged (see Figure 1). Although the basic principle of the tool is applicable to almost any type of mating connector assemblies, the specific geometry of the tool must match the pin-and-socket geometry of the specific mating assemblies to be inspected. In the original application for which the tool was conceived, each of the mating assemblies contains eight twinaxial connectors; the pin diameter is 0.014 in. (.0.35 mm), and the maximum allowable pin/socket misalignment is 0.007 in. (.0.18 mm). Incomplete connections can result in loss of flight data within the functional path to the space shuttle crew cockpit displays. The tool (see Figure 2) would consist mainly of a transparent disk with alignment clocking tabs that can be fitted onto either connector assembly. Sets of circles or equivalent reference markings are affixed to the face of the tool, located at the desired positions of the mating contact pairs. An inspector would simply fit the tool onto a connector assembly, engaging the clocking tabs until the tool fits tightly. The inspector would then align one set of circles positioning a line of sight perpendicular to one contact within the connector assembly. Mis alignments would be evidenced by the tip of a pin contact straying past the inner edge of the circle. Socket contact misalignments would be evidenced by a crescent-shaped portion of the white dielectric appearing within the circle. The tool could include a variable magnifier plus an illuminator that could be configured so as not to cast shadows.
Smith, Christopher R.↗
Workmanship Standards Personnel Training and Certification Explained
This slide presentation reviews the standards that NASA requires for workmanship and discusses the rationale and the NASA-STD-8739.x standard series. The training and certification of inspectors and operators is to guarantee that workmanship is qualified for NASA applications. The NASA workmanship standard documents review the standards for: Polymeric Applications, Surface Mount Technology, Soldered Electrical Connections, Crimp, Cable and Harnesses, Fiber Optic Terminations, including ANSI and IPC standards for Electrostatic Discharge Safety, Space Applications Electronic Hardware and Requirements for Soldered Electrical and Electronic Assemblies. It also reviews the certification requirements for appropriate personnel. It also reviews the various levels of trainers for the various requirements. There is also a review of calibration requirements for training equipment. Some variations on the curriculum are allowed. NASA requires operators and inspectors to be certified by their employer to ensure that oversight is being performed.
Plante, Jeannette F.↗
Software Method for Computed Tomography Cylinder Data Unwrapping, Re-slicing, and Analysis
A software method has been developed that is applicable for analyzing cylindrical and partially cylindrical objects inspected using computed tomography (CT). This method involves unwrapping and re-slicing data so that the CT data from the cylindrical object can be viewed as a series of 2D sheets (or flattened onion skins ) in addition to a series of top view slices and 3D volume rendering. The advantages of viewing the data in this fashion are as follows: (1) the use of standard and specialized image processing and analysis methods is facilitated having 2D array data versus a volume rendering; (2) accurate lateral dimensional analysis of flaws is possible in the unwrapped sheets versus volume rendering; (3) flaws in the part jump out at the inspector with the proper contrast expansion settings in the unwrapped sheets; and (4) it is much easier for the inspector to locate flaws in the unwrapped sheets versus top view slices for very thin cylinders. The method is fully automated and requires no input from the user except proper voxel dimension from the CT experiment and wall thickness of the part. The software is available in 32-bit and 64-bit versions, and can be used with binary data (8- and 16-bit) and BMP type CT image sets. The software has memory (RAM) and hard-drive based modes. The advantage of the (64-bit) RAM-based mode is speed (and is very practical for users of 64-bit Windows operating systems and computers having 16 GB or more RAM). The advantage of the hard-drive based analysis is one can work with essentially unlimited-sized data sets. Separate windows are spawned for the unwrapped/re-sliced data view and any image processing interactive capability. Individual unwrapped images and un -wrapped image series can be saved in common image formats. More information is available at http://www.grc.nasa.gov/WWW/OptInstr/ NDE_CT_CylinderUnwrapper.html.
Roth, Don J.↗
Johnson Space Center: Workmanship Training
Special processes require special skills, knowledge and experienced application. For over 15 years, the NASA Johnson Space Center's Receiving, Inspection and Test Facility (RITF) has provided Agency-wide NASA Workmanship Standards compliance training, issuing more than 500 to 800 training completion certificates annually. It is critical that technicians and inspectors are trained and that they maintain their proficiency to implement the applicable standards and specifications. Training services include "hands-on" training to engineers, technicians, and inspectors in the areas of electrostatic discharge (ESD), soldering, surface mount technology (SMT), crimping, conformal coating, and fiber-optic terminations.
Patterson, Ashley↗