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At least 433 records · Page 24

A function approximation approach to anomaly detection in propulsion system test data

Ground test data from propulsion systems such as the Space Shuttle Main Engine (SSME) can be automatically screened for anomalies by a neural network. The neural network screens data after being trained with nominal data only. Given the values of 14 measurements reflecting external influences on the SSME at a given time, the neural network predicts the expected nominal value of a desired engine parameter at that time. We compared the ability of three different function-approximation techniques to perform this nominal value prediction: a novel neural network architecture based on Gaussian bar basis functions, a conventional back propagation neural network, and linear regression. These three techniques were tested with real data from six SSME ground tests containing two anomalies. The basis function network trained more rapidly than back propagation. It yielded nominal predictions with, a tight enough confidence interval to distinguish anomalous deviations from the nominal fluctuations in an engine parameter. Since the function-approximation approach requires nominal training data only, it is capable of detecting unknown classes of anomalies for which training data is not available.

Whitehead, Bruce A.↗

STS-53 Space Shuttle mission report

The STS-53 Space Shuttle Program Mission Report provides a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and the Space Shuttle Main Engine (SSME) subsystems performance during the fifty-second flight of the Space Shuttle Program, and the fifteenth flight of the Orbiter vehicle Discovery (OV-103). In addition to the Orbiter, the flight vehicle consisted of an ET, which was designated as ET-49/LWT-42; three SSME's, which were serial numbers 2024, 2012, and 2017 in positions 1, 2, and 3, respectively; and two SRB's, which were designated BI-055. The lightweight RSRM's that were installed in each SRB were designated 360L028A for the left SRB, and 360L028B for the right SRB. The primary objective of this flight was to successfully deploy the Department of Defense 1 (DOD-1) payload. The secondary objectives of this flight were to perform the operations required by the Glow Experiment/Cryogenic Heat Pipe Experiment Payload (GCP); the Hand-Held, Earth-Oriented, Real-Time, Cooperative, User-Friendly, Location-Targeting and Environmental System (HERCULES); the Space Tissue Loss (STL); the Battlefield Laser Acquisition Sensor Test (BLAST); the Radiation Monitoring Equipment-III (RME-III); the Microcapsules in Space-1 (MIS-1); the Visual Function Tester-2 (VFT-2); the Cosmic Radiation Effects and Activation Monitor (CREAM); the Clouds Logic to Optimize Use of Defense Systems-1A (CLOUDS-1A); the Fluids Acquisition and Resupply Experiment (FARE); and the Orbital Debris Radar Calibration Spheres (ODERACS). In addition to presenting a summary of subsystem performance, this report also discusses each Orbiter, ET, SSME, SRB, and RSRM in-flight anomaly in the applicable section of the report. Listed in the discussion of each anomaly is the officially assigned tracking number as published by each Project Office in their respective Problem Tracking List. All times given in this report are in Greenwich mean time (G.m.t.) as well as mission elapsed time (MET).

Fricke, Robert W., Jr.↗

STS-54 Space Shuttle mission report

The STS-54 Space Shuttle Program Mission Report is a summary of the Orbiter, External Tank (ET), Solid Rocket Booster/Redesigned Solid Rocket Motor (SRB/RSRM), and the Space Shuttle Main Engine (SSME) subsystems performance during this fifty-third flight of the Space Shuttle Program, and the third flight of the Orbiter vehicle Endeavour (OV-105). In addition to the Orbiter, the flight vehicle consisted of an ET, which was designated ET-51; three SSME's, which were serial numbers 2019, 2033, and 2018 in positions 1, 2, and 3, respectively; and two retrievable and reusable SRB's which were designated BI-056. The lightweight RSRM's that were installed in each SRB were designated 360L029A for the left SRB, and 360L029B for the right SRB. The primary objectives of this flight were to perform the operations to deploy the Tracking and Data Relay Satellite-F/Inertial Upper Stage payload and to fulfill the requirements of the Diffuse X-Ray Spectrometer (DXS) payload. The secondary objective was to fly the Chromosome and Plant Cell Division in Space (CHROMEX), Commercial Generic Bioprocessing Apparatus (CGBA), Physiological and Anatomical Rodent Experiment (PARE), and the Solid Surface Combustion Experiment (SSCE). In addition to presenting a summary of subsystem performance, this report also discusses each Orbiter, ET, SSME, SRB, and RSRM in-flight anomaly in the applicable section of the report. The official tracking number for each in-flight anomaly, assigned by the cognizant project, is also shown. All times are given in Greenwich mean time (G.m.t.) and mission elapsed time (MET).

Fricke, Robert W., Jr.↗

Enhanced simulation software for rocket turbopump, turbulent, annular liquid seals

One of the main objectives of this work is to develop a new dynamic analysis for liquid annular seals with arbitrary profile and to analyze a general distorted interstage seal of the space shuttle main engine high pressure oxygen turbopump (SSME-ATD-HPOTP). The dynamic analysis developed is based on a method originally proposed by Nelson and Nguyen. A simpler scheme based on cubic splines is found to be computationally more efficient and has better convergence properties at higher eccentricities. The first order solution of the original analysis is modified by including a more exact solution that takes into account the variation of perturbed variables along the circumference. A new set of equations for dynamic analysis are derived based on this more general model. A unified solution procedure that is valid for both Moody's and Hirs' friction models is presented. Dynamic analysis is developed for three different models: constant properties, variable properties, and thermal effects with variable properties. Arbitrarily varying seal profiles in both axial and circumferential directions are considered. An example case of an elliptical seal with varying degrees of axial curvature is analyzed in detail. A case study based on predicted clearances of an interstage seal of the SSME-ATD-HPOTP is presented. Dynamic coefficients based on external specified load are introduced to analyze seals that support a preload. The other objective of this work is to study the effect of large rotor displacements of SSME-ATD-HPOTP on the dynamics of the annular seal and the resulting transient motion. One task is to identify the magnitude of motion of the rotor about the centered position and establish limits of effectiveness of using current linear models. This task is accomplished by solving the bulk flow model seal governing equations directly for transient seal forces for any given type of motion, including motion with large eccentricities. Based on the above study, an equivalence is established between linearized coefficients based transient motion and the same motion as predicted by the original governing equations. An innovative method is developed to model nonlinearities in an annular seal based on dynamic coefficients computed at various static eccentricities. This method is thoroughly tested for various types of transient motion using bulk flow model results as a benchmark.

Padavala, Satya↗

Develop advanced nonlinear signal analysis topographical mapping system

This study will provide timely assessment of SSME component operational status, identify probable causes of malfunction, and indicate feasible engineering solutions. The final result of this program will yield an advanced nonlinear signal analysis topographical mapping system (ATMS) of nonlinear and nonstationary spectral analysis software package integrated with the Compressed SSME TOPO Data Base (CSTDB) on the same platform. This system will allow NASA engineers to retrieve any unique defect signatures and trends associated with different failure modes and anomalous phenomena over the entire SSME test history across turbopump families.

Jong, Jen-Yi↗

Incompressible Navier-Stokes Calculations in Pump Flows

Flow through pump components, such as the SSME-HPFTP Impeller and an advanced rocket pump impeller, is efficiently simulated by solving the incompressible Navier-Stokes equations. The solution method is based on the pseudo compressibility approach and uses an implicit-upwind differencing scheme together with the Gauss-Seidel line relaxation method. The equations are solved in steadily rotating reference frames and the centrifugal force and the Coriolis force are added to the equation of motion. Current computations use one-equation Baldwin-Barth turbulence model which is derived from a simplified form of the standard k-epsilon model equations. The resulting computer code is applied to the flow analysis inside an 11-inch SSME High Pressure Fuel Turbopump impeller, and an advanced rocket pump impeller. Numerical results of SSME-HPFTP impeller flow are compared with experimental measurements. In the advanced pump impeller, the effects of exit and shroud cavities are investigated. Flow analyses at design conditions will be presented.

Kiris, Cetin↗

Investigation of the collision line broadening problem as applicable to the NASA Optical Plume Anomaly Detection (OPAD) system, phase 1

As a final report for phase 1 of the project, the researchers are submitting to the Tennessee Tech Office of Research the following two papers (reprinted in this report): 'Collision Line Broadening Effects on Spectrometric Data from the Optical Plume Anomaly System (OPAD),' presented at the 30th AIAA/ASME/SAE/ASEE Joint Propulsion Conference, 27-29 June 1994, and 'Calculation of Collision Cross Sections for Atomic Line Broadening in the Plume of the Space Shuttle Main Engine (SSME),' presented at the IEEE Southeastcon '95, 26-29 March 1995. These papers fully state the problem and the progress made up to the end of NASA Fiscal Year 1994. The NASA OPAD system was devised to predict concentrations of anomalous species in the plume of the Space Shuttle Main Engine (SSME) through analysis of spectrometric data. The self absorption of the radiation of these plume anomalies is highly dependent on the line shape of the atomic transition of interest. The Collision Line Broadening paper discusses the methods used to predict line shapes of atomic transitions in the environment of a rocket plume. The Voigt profile is used as the line shape factor since both Doppler and collisional line broadening are significant. Methods used to determine the collisional cross sections are discussed and the results are given and compared with experimental data. These collisional cross sections are then incorporated into the current self absorbing radiative model and the predicted spectrum is compared to actual spectral data collected from the Stennis Space Center Diagnostic Test Facility rocket engine. The second paper included in this report investigates an analytical method for determining the cross sections for collision line broadening by molecular perturbers, using effective central force interaction potentials. These cross sections are determined for several atomic species with H2, one of the principal constituents of the SSME plume environment, and compared with experimental data.

Dean, Timothy C.↗

Automated Propulsion Data Screening demonstration system

A fully-instrumented firing of a propulsion system typically generates a very large quantity of data. In the case of the Space Shuttle Main Engine (SSME), data analysis from ground tests and flights is currently a labor-intensive process. Human experts spend a great deal of time examining the large volume of sensor data generated by each engine firing. These experts look for any anomalies in the data which might indicate engine conditions warranting further investigation. The contract effort was to develop a 'first-cut' screening system for application to SSME engine firings that would identify the relatively small volume of data which is unusual or anomalous in some way. With such a system, limited and expensive human resources could focus on this small volume of unusual data for thorough analysis. The overall project objective was to develop a fully operational Automated Propulsion Data Screening (APDS) system with the capability of detecting significant trends and anomalies in transient and steady-state data. However, the effort limited screening of transient data to ground test data for throttle-down cases typical of the 3-g acceleration, and for engine throttling required to reach the maximum dynamic pressure limits imposed on the Space Shuttle. This APDS is based on neural networks designed to detect anomalies in propulsion system data that are not part of the data used for neural network training. The delivered system allows engineers to build their own screening sets for application to completed or planned firings of the SSME. ERC developers also built some generic screening sets that NASA engineers could apply immediately to their data analysis efforts.

Hoyt, W. Andes↗

Impact of uncertainty on modeling and testing

A thorough understanding of the uncertainties associated with the modeling and testing of the Space Shuttle Main Engine (SSME) Engine will greatly aid decisions concerning hardware performance and future development efforts. This report will describe the determination of the uncertainties in the modeling and testing of the Space Shuttle Main Engine test program at the Technology Test Bed facility at Marshall Space Flight Center. Section 2 will present a summary of the uncertainty analysis methodology used and discuss the specific applications to the TTB SSME test program. Section 3 will discuss the application of the uncertainty analysis to the test program and the results obtained. Section 4 presents the results of the analysis of the SSME modeling effort from an uncertainty analysis point of view. The appendices at the end of the report contain a significant amount of information relative to the analysis, including discussions of venturi flowmeter data reduction and uncertainty propagation, bias uncertainty documentations, technical papers published, the computer code generated to determine the venturi uncertainties, and the venturi data and results used in the analysis.

Coleman, Hugh W.↗

A Note of Appreciation for the MUS

This note has been written to acknowledge the pervasive impact the Method of Universal Slopes (MUS) has had on the design and development of the Space Shuttle Main Engine (SSME) through its use in material fatigue properties definition for component analysis. Included is a brief historical perspective describing propulsion system development leading up to the SSME, the need for fatigue analysis capability in the SSME design, the role that MUS played in meeting that need as a material modeling tool and the engine's subsequent successful operating history.

Newell, J. F.↗

Evolutionary Development of the Simulation by Logical Modeling System (SIBYL)

Through the evolutionary development of the Simulation by Logical Modeling System (SIBYL) we have re-engineered the expensive and complex IBM mainframe based Long-term Hardware Projection Model (LHPM) to a robust cost-effective computer based mode that is easy to use. We achieved significant cost reductions and improved productivity in preparing long-term forecasts of Space Shuttle Main Engine (SSME) hardware. The LHPM for the SSME is a stochastic simulation model that projects the hardware requirements over 10 years. SIBYL is now the primary modeling tool for developing SSME logistics proposals and Program Operating Plan (POP) for NASA and divisional marketing studies.

Wu, Helen↗

Space Shuttle Main Engine Quantitative Risk Assessment: Illustrating Modeling of a Complex System with a New QRA Software Package

During 1997, a team from Hernandez Engineering, MSFC, Rocketdyne, Thiokol, Pratt & Whitney, and USBI completed the first phase of a two year Quantitative Risk Assessment (QRA) of the Space Shuttle. The models for the Shuttle systems were entered and analyzed by a new QRA software package. This system, termed the Quantitative Risk Assessment System(QRAS), was designed by NASA and programmed by the University of Maryland. The software is a groundbreaking PC-based risk assessment package that allows the user to model complex systems in a hierarchical fashion. Features of the software include the ability to easily select quantifications of failure modes, draw Event Sequence Diagrams(ESDs) interactively, perform uncertainty and sensitivity analysis, and document the modeling. This paper illustrates both the approach used in modeling and the particular features of the software package. The software is general and can be used in a QRA of any complex engineered system. The author is the project lead for the modeling of the Space Shuttle Main Engines (SSMEs), and this paper focuses on the modeling completed for the SSMEs during 1997. In particular, the groundrules for the study, the databases used, the way in which ESDs were used to model catastrophic failure of the SSMES, the methods used to quantify the failure rates, and how QRAS was used in the modeling effort are discussed. Groundrules were necessary to limit the scope of such a complex study, especially with regard to a liquid rocket engine such as the SSME, which can be shut down after ignition either on the pad or in flight. The SSME was divided into its constituent components and subsystems. These were ranked on the basis of the possibility of being upgraded and risk of catastrophic failure. Once this was done the Shuttle program Hazard Analysis and Failure Modes and Effects Analysis (FMEA) were used to create a list of potential failure modes to be modeled. The groundrules and other criteria were used to screen out the many failure modes that did not contribute significantly to the catastrophic risk. The Hazard Analysis and FMEA for the SSME were also used to build ESDs that show the chain of events leading from the failure mode occurence to one of the following end states: catastrophic failure, engine shutdown, or siccessful operation( successful with respect to the failure mode under consideration).

Smart, Christian↗

Spares Management : Optimizing Hardware Usage for the Space Shuttle Main Engine

The complexity of the Space Shuttle Main Engine (SSME), combined with mounting requirements to reduce operations costs have increased demands for accurate tracking, maintenance, and projections of SSME assets. The SSME Logistics Team is developing an integrated asset management process. This PC-based tool provides a user-friendly asset database for daily decision making, plus a variable-input hardware usage simulation with complex logic yielding output that addresses essential asset management issues. Cycle times on critical tasks are significantly reduced. Associated costs have decreased as asset data quality and decision-making capability has increased.

Gulbrandsen, K. A.↗

Advanced Transportation System Studies. Technical Area 3: Alternate Propulsion Subsystem Concepts: Executive Summary - Volume 1

The Alternate Propulsion Subsystem Concepts contract had seven tasks defined that are reported under this contract deliverable. The tasks were: FAA Restart Study, J-2S Restart Study, Propulsion Database Development. SSME Upper Stage Use. CERs for Liquid Propellant Rocket Engines. Advanced Low Cost Engines, and Tripropellant Comparison Study. The two restart studies, F-1A and J-2S, generated program plans for restarting production of each engine. Special emphasis was placed on determining changes to individual parts due to obsolete materials, changes in OSHA and environmental concerns, new processes available, and any configuration changes to the engines. The Propulsion Database Development task developed a database structure and format which is easy to use and modify while also being comprehensive in the level of detail available. The database structure included extensive engine information and allows for parametric data generation for conceptual engine concepts. The SSME Upper Stage Use task examined the changes needed or desirable to use the SSME as an upper stage engine both in a second stage and in a translunar injection stage. The CERs for Liquid Engines task developed qualitative parametric cost estimating relationships at the engine and major subassembly level for estimating development and production costs of chemical propulsion liquid rocket engines. The Advanced Low Cost Engines task examined propulsion systems for SSTO applications including engine concept definition, mission analysis. trade studies. operating point selection, turbomachinery alternatives, life cycle cost, weight definition. and point design conceptual drawings and component design. The task concentrated on bipropellant engines, but also examined tripropellant engines. The Tripropellant Comparison Study task provided an unambiguous comparison among various tripropellant implementation approaches and cycle choices, and then compared them to similarly designed bipropellant engines in the SSTO mission This volume overviews each of the tasks giving its objectives, main results. and conclusions. More detailed Final Task Reports are available on each individual task.

Levack, Daniel J. H.↗

Space Shuttle Main Engine: Thirty Years of Innovation

The Space Shuttle Main Engine (SSME) is the first reusable, liquid booster engine designed for human space flight. This paper chronicles the 30-year history and achievements of the SSME from authority to proceed up to the latest flight configuration - the Block 2 SSME.

Jue, F. H.↗

Time-Dependent Simulations of Incompressible Flow in a Turbopump Using Overset Grid Approach

This viewgraph presentation provides information on mathematical modelling of the SSME (space shuttle main engine). The unsteady SSME-rig1 start-up procedure from the pump at rest has been initiated by using 34.3 million grid points. The computational model for the SSME-rig1 has been completed. Moving boundary capability is obtained by using DCF module in OVERFLOW-D. MPI (Message Passing Interface)/OpenMP hybrid parallel code has been benchmarked.

Kiris, Cetin↗

Turnaround Time Modeling for Conceptual Rocket Engines

Recent years have brought about a paradigm shift within NASA and the Space Launch Community regarding the performance of conceptual design. Reliability, maintainability, supportability, and operability are no longer effects of design; they have moved to the forefront and are affecting design. A primary focus of this shift has been a planned decrease in vehicle turnaround time. Potentials for instituting this decrease include attacking the issues of removing, refurbishing, and replacing the engines after each flight. less, it is important to understand the operational affects of an engine on turnaround time, ground support personnel and equipment. One tool for visualizing this relationship involves the creation of a Discrete Event Simulation (DES). A DES model can be used to run a series of trade studies to determine if the engine is meeting its requirements, and, if not, what can be altered to bring it into compliance. Using DES, it is possible to look at the ways in which labor requirements, parallel maintenance versus serial maintenance, and maintenance scheduling affect the overall turnaround time. A detailed DES model of the Space Shuttle Main Engines (SSME) has been developed. Trades may be performed using the SSME Processing Model to see where maintenance bottlenecks occur, what the benefits (if any) are of increasing the numbers of personnel, or the number and location of facilities, in addition to trades previously mentioned, all with the goal of optimizing the operational turnaround time and minimizing operational cost. The SSME Processing Model was developed in such a way that it can easily be used as a foundation for developing DES models of other operational or developmental reusable engines. Performing a DES on a developmental engine during the conceptual phase makes it easier to affect the design and make changes to bring about a decrease in turnaround time and costs.

Nix, Michael↗

The Role of Structural Dynamics and Testing in the Shuttle Flowliner Crack Investigation

During a normal inspection of the main propulsion system at Kennedy Space Center, small cracks were noticed near a slotted region of a gimbal joint flowliner located just upstream from one of the Space Shuttle Main Engines (SSME). These small cracks sparked an investigation of the entire Space Shuttle fleet main propulsion feedlines. The investigation was initiated to determine the cause of the small cracks and a repair method that would be needed to return the Shuttle fleet back to operation safely. The cracks were found to be initiated by structural resonance caused by flow fluctuations from the SSME low pressure fuel turbopump interacting with the flowliner. The pump induced backward traveling wakes that excited the liner and duct acoustics which also caused the liner to vibrate in complex mode shapes. The investigation involved an extensive effort by a team of engineers from the NASA civil servant and contractor workforce with the goal to characterize the root cause of the cracking behavior of the fuel side gimbal joint flowliners. In addition to working to identify the root cause, a parallel path was taken to characterize the material properties and fatigue capabilities of the liner material such that the life of the liners could be ascertained. As the characterization of the material and the most probable cause matured, the combination of the two with pump speed restrictions provided a means to return the Shuttle to flight in a safe manner. This paper traces the flowliner investigation results with respect to the structural dynamics analysis, component level testing and hot-fire flow testing on a static testbed. The paper will address the unique aspects of a very complex problem involving backflow from a high performance pump that has never been characterized nor understood to such detail. In addition, the paper will briefly address the flow phenomena that excited the liners, the unique structural dynamic modal characteristics and the variability of SSME operation which has ultimately ensured the safe and reliable operation of the shuttle main engines for each flight.

Frady, Gregory P.↗