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At least 379 records · Page 21

Model-Based SMA Initiative Phase 1 Report: Reliability Tips Excerpt

The emergence of model-based engineering, with Model- Based Systems Engineering (MBSE) leading the way, is transforming design and analysis methodologies. [7] 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 designs. Therefore Reliability Engineers (REs) supporting NASA missions must be integrated into model-based engineering, using these recommended modeling techniques, to ensure the outputs of their analyses are relevant and value-needed to the design, development, and operational processes for failure risk assessment and communication.

Nancy J. Lindsey↗

Materials considerations in the design of a metal-hydride heat pump for an advanced extravehicular mobility unit

A metal-hydride heat pump (HHP) has been proposed to provide an advanced regenerable nonventing thermal sink for the liquid-cooled garment worn during an extravehicular activity (EVA). The conceptual design indicates that there is a potential for significant advantages over the one presently being used by shuttle crew personnel as well as those that have been proposed for future use with the space station. Compared to other heat pump designs, a HHP offers the potential for extended use with no electrical power requirements during the EVA. In addition, a reliable, compact design is possible due to the absence of moving parts other than high-reliability check valves. Because there are many subtleties in the properties of metal hydrides for heat pump applications, it is essential that a prototype hydride heat pump be constructed with the selected materials before a committment is made for the final design. Particular care must be given to the evaporator heat exchanger worn by the astronaut since the performance of hydride heat pumps is generally heat transfer limited.

Liebert, B. E.↗

Microgravity Storage Vessels and Conveying-Line Feeders for Cohesive Regolith

Under microgravity, the usual methods of placing granular solids into, or extracting them from, containers or storage vessels will not function. Alternative methods are required to provide a motive force to move the material. New configurations for microgravity regolith storage vessels that do not resemble terrestrial silos, hoppers, or tanks are proposed. The microgravity-compatible bulk-material storage vessels and exit feed configurations are designed to reliably empty and feed cohesive material to transfer vessels or conveying ducts or lines without gravity. A controllable motive force drives the cohesive material to the exit opening(s), and provides a reliable means to empty storage vessels and/or to feed microgravity conveying lines. The proposed designs will function equally well in vacuum, or inside of pressurized enclosures. Typical terrestrial granular solids handling and storage equipment will not function under microgravity, since almost all such equipment relies on gravity to at least move material to an exit location or to place it in the bottom of a container. Under microgravity, there effectively are no directions of up or down, and in order to effect movement of material, some other motive force must be applied to the material. The proposed storage vessels utilize dynamic centrifugal force to effect movement of regolith whenever material needs to be removed from the storage vessel. During simple storage, no dynamic motion or forces are required. The rotation rate during emptying can be controlled to ensure that material will move to the desired exit opening, even if the material is highly cohesive, or has acquired an electrostatic charge. The general concept of this Swirl Action Utilized for Centrifugal Ejection of Regolith (SAUCER) microgravity storage unit/dynamic feeder is to have an effective slot-hopper (based on the converging angles of the top and bottom conical section of the vessel) with an exit slot around the entire periphery of the SAUCER. The basic shape of such a unit is like two Chinese straw hats (douli) - one upside down, on the bottom, and another on top; or two wokpans, one upright on the bottom and another inverted on top, with a small gap between the upright and inverted pans or hats (around the periphery). A stationary outer ring, much like an unmounted bicycle tire, surrounds the gap between the two coaxial, nearly conical pieces, forming the top and bottom of the unit.

Walton, Otis R.↗

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↗

Redundancy: How Many Unreliable Spares are Needed for High Reliability and Confidence on a Time Limited Mission?

This paper investigates the number of redundant units needed to achieve high reliability with high confidence. The approach applies to the case where the unit failure rate is too high for a single unit to provide the required reliability over the mission duration. To achieve high reliability, the design then uses N redundant units, one operating unit and N – 1 spares. If the unit failure rate is f, the mission length is L, and f * L is small (not the case assumed here), the unit failure probability over the mission duration is F1 = f * L << 1. In this case, the probability that all N units will fail is FN = F1N, and the needed N = LN(FN)/LN(F1). For the case of large f * L assumed here, F1 = f * L > 1, and F1 is the expected number of failures during the mission. The needed redundancy, N, to achieve the specified N unit reliability, FN, can be computed using the cumulative Poisson distribution with mean equal to F1. The number of spares, N - 1, is increased until the probability - that the total number of failures will be less than N -1 - achieves the required reliability. The confidence that this reliability can be achieved can be computed using the cumulative Poisson distribution or the chi-square distribution. Since the measured unit failure rate, f, has some uncertainty, the confidence that the rate is not lower than the actual failure rate and the required reliability is not overestimated is about 50%. Adding more redundant units increases the confidence that the required reliability, FN, will be achieved. For a fixed number of redundant units, the expected reliability and confidence can be traded off, since lower reliability goals have higher confidence in being achieved. Both the required reliability and confidence can be specified initially and the needed number of redundant units computed using the measured failure rate. The unit failure rate is determined by initial reliability growth testing to remove design errors and to better estimate the final constant failure rate. Reducing the failure rate and reducing its variance both reduce the number of redundant units needed for the required reliability and confidence. Since the total cost is the sum of the costs of the units and of the testing, there is an optimum test time that produces minimum cost.

Harry W. Jones↗

Development of a reliable Potting process for Photoconductive Semiconductor Switches (PCSS)

Electrical potting is an important process to protect semiconductor devices from damaging external elements (mechanical stress, moisture, high voltage, etc.) and provides structural support for delicate devices for electrical connectivity to a larger platform. This internship will focus on the development of a universal potting jig for photoconductive semiconductor switches (PCSS). The goal is to design a reliable compression jig that is cross compatible with various PCSS designs that allow for easy potting of devices with a high dielectric breakdown strength material. The challenge with the current potting jig is that the design is only compatible with one style of PCSS and applies uneven pressure that can lead to leakage of potting material. Our approach is to move from a design that applies pressure by binder clip to utilizing a micrometer based compressing jig for a reliable packaging process that can pot a variety of devices without having to have a unique compressing jig for each of style of PCSS. Possible roadblocks with the new design include epoxy leakage into the optical path and misalignment of the electrode – metal contact bond.

42 ENGINEERING↗

A study of multiplex data bus techniques for the space shuttle

A comprehensive technology base for the design of a multiplexed data bus subsystem is provided. Extensive analyses, both analytical and empirical, were performed. Subjects covered are classified under the following headings: requirements identification and analysis; transmission media studies; signal design and detection studies; synchronization, timing, and control studies; user-subsystem interface studies; operational reliability analyses; design of candidate data bus configurations; and evaluation of candidate data bus designs.

Kearney, R. J.↗

An expert system for integrated structural analysis and design optimization for aerospace structures

The results of a research study on the development of an expert system for integrated structural analysis and design optimization is presented. An Object Representation Language (ORL) was developed first in conjunction with a rule-based system. This ORL/AI shell was then used to develop expert systems to provide assistance with a variety of structural analysis and design optimization tasks, in conjunction with procedural modules for finite element structural analysis and design optimization. The main goal of the research study was to provide expertise, judgment, and reasoning capabilities in the aerospace structural design process. This will allow engineers performing structural analysis and design, even without extensive experience in the field, to develop error-free, efficient and reliable structural designs very rapidly and cost-effectively. This would not only improve the productivity of design engineers and analysts, but also significantly reduce time to completion of structural design. An extensive literature survey in the field of structural analysis, design optimization, artificial intelligence, and database management systems and their application to the structural design process was first performed. A feasibility study was then performed, and the architecture and the conceptual design for the integrated 'intelligent' structural analysis and design optimization software was then developed. An Object Representation Language (ORL), in conjunction with a rule-based system, was then developed using C++. Such an approach would improve the expressiveness for knowledge representation (especially for structural analysis and design applications), provide ability to build very large and practical expert systems, and provide an efficient way for storing knowledge. Functional specifications for the expert systems were then developed. The ORL/AI shell was then used to develop a variety of modules of expert systems for a variety of modeling, finite element analysis, and design optimization tasks in the integrated aerospace structural design process. These expert systems were developed to work in conjunction with procedural finite element structural analysis and design optimization modules (developed in-house at SAT, Inc.). The complete software, AutoDesign, so developed, can be used for integrated 'intelligent' structural analysis and design optimization. The software was beta-tested at a variety of companies, used by a range of engineers with different levels of background and expertise. Based on the feedback obtained by such users, conclusions were developed and are provided.

Source record↗

Cost-Effective High Reliability for Space Life Support Requires Using Storage

Cost-effective high reliability can be achieved in future space life support systems through careful systems analysis and design. This paper outlines a comprehensive approach. Potential future human space missions are described. The mission parameter impacts on life support system design and reliability requirements are discussed. Not all human space missions require high reliability life support. The potential reliability and cost of storage and of recycling life support systems are investigated. Simple storage systems can provide cost-effective high reliability life support where it is needed. More complex recycling systems with lower reliability and higher cost can be used when suitable.

Jones, Harry W.↗

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↗

Portable and Cost-Effective Device for Reliable Detection of Counterfeit and Non-compliant Refrigerants in Diverse Applications

Counterfeit refrigerants pose significant challenges to safety, system reliability, and operational effectiveness due to their harmful contaminants or incompatible chemical compositions. Utilizing these noncompliant products can lead to reduced efficiency, equipment failures, and expensive repairs. Additionally, heightened demand for alternative refrigerants during the industry's transition has created supply gaps, enabling counterfeit products to proliferate. Accurate detection and analysis tools are therefore essential to verify refrigerant authenticity and ensure system integrity in diverse applications. This paper presents the development of a portable device designed for reliable identification and detailed analysis of refrigerant composition. By integrating precision gas sampling, controlled pressure regulation, and automated sensor technology, the device not only detects deviations from standard refrigerant properties but also provides a comprehensive composition breakdown. Pre-calibrated sensors measure the refrigerant gas to identify specific concentrations and contaminants, with an intuitive LED-based indicator system ensuring quick interpretation of results. The user-friendly interface enables operators to select refrigerant types for targeted testing, further enhancing accuracy and usability for field technicians. Comprehensive testing was conducted on mildly flammable A2L refrigerants, showcasing the device’s robustness and adaptability in analyzing composition and detecting discrepancies. The device demonstrated consistent accuracy across a range of refrigerant samples, affirming its reliability in diverse operational environments. Its design minimizes contamination risks during sampling and provides detailed composition results within 90 seconds, ensuring efficient and precise analysis. With a projected price point under $150, the proposed solution delivers affordability alongside its lightweight portability and straightforward operation. Unlike complex and costly alternatives, such as gas chromatography systems, this device provides an accessible option for technicians, customs personnel, and industry operators in need of quick and effective refrigerant verification. Compatible with both current formulations and emerging refrigerant technologies, the device addresses critical counterfeit detection needs across a range of applications. By delivering accurate composition analysis and counterfeit identification, this innovation enhances system performance, safety, and operational reliability in crucial industries.

Cheekatamarla, Praveen [ORNL] (ORCID:0000000248827↗

The Outer Planet Mariner Spacecraft

The Mariner Jupiter/Saturn 1977 Spacecraft is designed to conduct a broad range of intensive investigations of the Jupiter and Saturn planetary systems, and of the interplanetary medium from earth to beyond Saturn. The spacecraft design has evolved from earlier Mariners, the Viking Orbiter, and the technology available for implementing long-life, reliable spacecraft designs. A description of the design is presented, and adaptations of that design for Jupiter/Uranus, Jupiter Orbiter, probe carrying, and mini-satellite carrying missions are discussed.

Draper, R. F.↗

Effect of Cyclic Thermo-Mechanical Loads on Fatigue Reliability in Polymer Matrix Composites

A methodology to compute probabilistic fatigue life of polymer matrix laminated composites has been developed and demonstrated. Matrix degradation effects caused by long term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress dependent multi-factor interaction relationship developed at NASA Lewis Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability- based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/- 45/90)(sub s) graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical cyclic loads and low thermal cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical cyclic loads and high thermal cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Shah, A. R.↗

Probabilistic Simulation of Combined Thermo-Mechanical Cyclic Fatigue in Composites

A methodology to compute probabilistically-combined thermo-mechanical fatigue life of polymer matrix laminated composites has been developed and is demonstrated. Matrix degradation effects caused by long-term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress-dependent multifactor-interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability-integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/-45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical-cyclic loads and low thermal-cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical-cyclic loads and high thermal-cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Chamis, Christos C.↗

Probabilistic Simulation for Combined Cycle Fatigue in Composites

A methodology to compute probabilistic fatigue life of polymer matrix laminated composites has been developed and demonstrated. Matrix degradation effects caused by long term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress dependent multifactor interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/- 45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical cyclic loads and low thermal cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical cyclic loads and high thermal cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Chamis, Christos C.↗

Probabilistic Simulation of Combined Thermo-Mechanical Cyclic Fatigue in Composites

A methodology to compute probabilistically-combined thermo-mechanical fatigue life of polymer matrix laminated composites has been developed and is demonstrated. Matrix degradation effects caused by long-term environmental exposure and mechanical/thermal cyclic loads are accounted for in the simulation process. A unified time-temperature-stress-dependent multifactor-interaction relationship developed at NASA Glenn Research Center has been used to model the degradation/aging of material properties due to cyclic loads. The fast probability-integration method is used to compute probabilistic distribution of response. Sensitivities of fatigue life reliability to uncertainties in the primitive random variables (e.g., constituent properties, fiber volume ratio, void volume ratio, ply thickness, etc.) computed and their significance in the reliability-based design for maximum life is discussed. The effect of variation in the thermal cyclic loads on the fatigue reliability for a (0/+/-45/90)s graphite/epoxy laminate with a ply thickness of 0.127 mm, with respect to impending failure modes has been studied. The results show that, at low mechanical-cyclic loads and low thermal-cyclic amplitudes, fatigue life for 0.999 reliability is most sensitive to matrix compressive strength, matrix modulus, thermal expansion coefficient, and ply thickness. Whereas at high mechanical-cyclic loads and high thermal-cyclic amplitudes, fatigue life at 0.999 reliability is more sensitive to the shear strength of matrix, longitudinal fiber modulus, matrix modulus, and ply thickness.

Chamis, Christos C.↗

Thermomechanical Reliability Aspects of Automotive Power Electronics: Current Status and Future Trends

Common failure locations (e.g., wire bonds, solder interface) and mechanisms within traditional automotive power electronics package designs and reliability concerns associated with packaging at higher temperatures and higher heat fluxes will be discussed. Examples of packaging solutions that increase mechanical reliability will be presented and state-of-health (SOH) estimation using offline and online (in situ) techniques will be described.

ADVANCED PROPULSION SYSTEMS,DIRECT ENERGY CONVERSI↗