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NASA NTRS1994

Dexterous end effector flight demonstration

The Dexterous End Effector Flight Experiment is a flight demonstration of newly developed equipment and methods which make for more dexterous manipulation of robotic arms. The following concepts are to be demonstrated: The Force Torque Sensor is a six axis load cell located at the end of the RMS which displays load data to the operator on the orbiter CCTV monitor. TRAC is a target system which provides six axis positional information to the operator. It has the characteristic of having high sensitivity to attitude misalignment while being flat. AUTO-TRAC is a variation of TRAC in which a computer analyzes a target, displays translational and attitude misalignment information, and provides cues to the operator for corrective inputs. The Magnetic End Effector is a fault tolerant end effector which grapples payloads using magnetic attraction. The Carrier Latch Assembly is a fault tolerant payload carrier, which uses mechanical latches and/or magnetic attraction to hold small payloads during launch/landing and to release payloads as desired. The flight experiment goals and objectives are explained. The experiment equipment is described, and the tasks to be performed during the demonstration are discussed.

Carter, Edward L.↗

NASA NTRS2006

Real-Time Rocket/Vehicle System Integrated Health Management Laboratory For Development and Testing of Health Monitoring/Management Systems

Pratt & Whitney Rocketdyne has developed a real-time engine/vehicle system integrated health management laboratory, or testbed, for developing and testing health management system concepts. This laboratory simulates components of an integrated system such as the rocket engine, rocket engine controller, vehicle or test controller, as well as a health management computer on separate general purpose computers. These general purpose computers can be replaced with more realistic components such as actual electronic controllers and valve actuators for hardware-in-the-loop simulation. Various engine configurations and propellant combinations are available. Fault or failure insertion capability on-the-fly using direct memory insertion from a user console is used to test system detection and response. The laboratory is currently capable of simulating the flow-path of a single rocket engine but work is underway to include structural and multiengine simulation capability as well as a dedicated data acquisition system. The ultimate goal is to simulate as accurately and realistically as possible the environment in which the health management system will operate including noise, dynamic response of the engine/engine controller, sensor time delays, and asynchronous operation of the various components. The rationale for the laboratory is also discussed including limited alternatives for demonstrating the effectiveness and safety of a flight system.

Aguilar, R.↗

NASA NTRS2020

The Mars 2020 lander vision system field test

The Mars 2020 Lander Vision System estimates position relative to a map and provides this information to the spacecraft so that large hazards can be avoided during landing. The LVS is a new mission critical sensor and as such requires extensive validation. A field test conducted in May 2019 was the primary means to prove that the LVS will operate as designed. During this test over 600 independent real-time runs on engineering model LVS hardware and software were executed and clearly showed that it could meet a 40m position estimation requirement over a wide operational envelope. This paper will describe the test approach, operations and results. Specific examples as well as aggregate performance will be discussed along with off-nominal testing and fault recovery.

Montgomery, J.↗

NASA NTRS2012

Extended Testability Analysis Tool

The Extended Testability Analysis (ETA) Tool is a software application that supports fault management (FM) by performing testability analyses on the fault propagation model of a given system. Fault management includes the prevention of faults through robust design margins and quality assurance methods, or the mitigation of system failures. Fault management requires an understanding of the system design and operation, potential failure mechanisms within the system, and the propagation of those potential failures through the system. The purpose of the ETA Tool software is to process the testability analysis results from a commercial software program called TEAMS Designer in order to provide a detailed set of diagnostic assessment reports. The ETA Tool is a command-line process with several user-selectable report output options. The ETA Tool also extends the COTS testability analysis and enables variation studies with sensor sensitivity impacts on system diagnostics and component isolation using a single testability output. The ETA Tool can also provide extended analyses from a single set of testability output files. The following analysis reports are available to the user: (1) the Detectability Report provides a breakdown of how each tested failure mode was detected, (2) the Test Utilization Report identifies all the failure modes that each test detects, (3) the Failure Mode Isolation Report demonstrates the system s ability to discriminate between failure modes, (4) the Component Isolation Report demonstrates the system s ability to discriminate between failure modes relative to the components containing the failure modes, (5) the Sensor Sensor Sensitivity Analysis Report shows the diagnostic impact due to loss of sensor information, and (6) the Effect Mapping Report identifies failure modes that result in specified system-level effects.

Melcher, Kevin↗

NASA NTRS2008

Enhanced Self Tuning On-Board Real-Time Model (eSTORM) for Aircraft Engine Performance Health Tracking

A key technological concept for producing reliable engine diagnostics and prognostics exploits the benefits of fusing sensor data, information, and/or processing algorithms. This report describes the development of a hybrid engine model for a propulsion gas turbine engine, which is the result of fusing two diverse modeling methodologies: a physics-based model approach and an empirical model approach. The report describes the process and methods involved in deriving and implementing a hybrid model configuration for a commercial turbofan engine. Among the intended uses for such a model is to enable real-time, on-board tracking of engine module performance changes and engine parameter synthesis for fault detection and accommodation.

Volponi, Al↗

NASA NTRS2010

Space Shuttle Main Engine Liquid Air Insulation Redesign Lessons Learned

The Space Shuttle Main Engine Liquid Air Insulation redesign was required to prevent the reoccurance of the STS-111 High Pressure Speed Sensor In-Flight Anomaly. The STS-111 In-Flight Anomaly Failure Investigation Team's initial redesign of the High Pressure Fuel Turbopump Pump End Ball Bearing Liquid Air Insulation failed the certification test by producing Liquid Air. The certification test failure indicated not only the High Pressure Fuel Turbopump Liquid Air Insulation, but all other Space Shuttle Main Engine Liquid Air Insulation. This paper will document the original Space Shuttle Main Engine Liquid Air STS-111 In-Flight Anomaly investigation, the heritage Space Shuttle Main Engine Insulation certification testing faults, the techniques and instrumentation used to accurately test the Liquid Air Insulation systems on the Stennis Space Center SSME test stand, the analysis techniques used to identify the Liquid Air Insulation problem areas and the analytical verification of the redesign before entering certification testing, Trade study down selected to three potential design solutions, the results of the development testing which down selected the final Liquid Air Redesign are also documented within this paper.

Darrell Gaddy↗

NASA NTRS2020

The Mars 2020 Lander Vision System Field Test

The Mars 2020 Lander Vision System estimates position relative to a map and provides this information to the spacecraft so that large hazards can be avoided during landing. The LVS is a new mission critical sensor and as such requires extensive validation. A field test conducted in May 2019 was the primary means to prove that the LVS will operate as designed. During this test over 600 independent real-time runs on engineering model LVS hardware and software were executed and clearly showed that it could meet a 40m position estimation requirement over a wide operational envelope. This paper will describe the test approach, operations and results. Specific examples as well as aggregate per-formance will be discussed along with off-nominal testing and fault recovery.

Johnson, A.↗

NASA NTRS2019

Image-Based Localization of Ultraviolet Corona

Systems and methods for identifying a fault in an electrical distribution system may include capturing an image of a corona event associated with a component of the electrical distribution system and processing the image of the corona event to identify the center and boundary of the corona event. An overlay for display with the image of the corona event may be generated, where the overlay identifying at least a center of the corona event and may be displayed to a user via a user interface device. In some cases, an unmanned aerial vehicle may comprise one or more image sensors capable of capturing the image of the corona event and communicate the images to a remote device for processing and display to the user. The image captured by the image sensors may include an ultraviolet image, a visible spectrum image, an infrared image, or a combination of image types.

Moore, Andrew J.↗

NASA NTRSDate not supplied

A Case Study on the Challenges and Opportunities for the Deployment of PHM Capabilities in Existing Engineering Systems

The field of Prognostics and Health Management (PHM) of engineering systems has experienced considerable growth over the last decade. From benefits associated with faster and more powerful hardware in the form of wireless sensors, edge devices, and general computing capabilities (GPU’s and cloud computing), to development of powerful algorithms for anomaly detection and remaining useful life (RUL) estimation, the number of engineering systems featuring advanced diagnostics and prognostics capabilities continues to grow at an increasingly faster pace. However, the deployment of PHM capabilities as part of the upgrade of existing engineering systems presents multiple challenges to the PHM practitioner charged with retrofitting such systems. Issues include a lack of specific instrumentation needed to capture the signals of interest; insufficient data and sampling rates required for fault detection and diagnosis, and for detection of failure/degradation indicators; and difficulties in the identification of a system’s nominal behavior as a result of age induced degradation. Today’s PHM practitioner must be able to quickly identify and assess these types of issues to effectively evaluate and select the optimal PHM strategies required to achieve the desired results. This paper presents results from the preliminary evaluation of the High-Pressure Gas Facility (HPGF) infrastructure at NASA’s Stennis Space Center in Hancock County, Mississippi. This evaluation is part of a feasibility study conducted prior to the deployment of prognostics and diagnostics capabilities in the pumps skids of the liquid nitrogen (LN2) system of the HPGF.

Condition Based Maintenance↗

NASA NTRS2022

Actuator and Motor Control End-to-End V&V on the Mars 2020 Rover

The Mars 2020 Perseverance rover is the most advanced robotic exploration system ever sent to another planet. To support the complex scientific and mobility needs of the mission, the rover utilizes 33 actuators, three multi-degree-of-freedom force-torque sensors, fifteen single or dual-speed resolvers, two solenoid valves, and twelve contact switches. The control for these actuators and sensors is achieved by several levels of flight software, coordinated between two computers with varying bandwidth control loops. Furthermore, the actuators and sensors were integrated into multiple larger robotic mechanisms that were delivered by different organizations at various points in the Integration and Test (I&T) timeline. All of this created a very complex Verification and Validation (V&V) scenario involving multiple subsystems and teams, several hardware and software testbeds with varying levels of fidelity, and significant systems engineering to ensure the overall I&T schedule could be maintained while ensuring system hardware safety.This paper details the integrated V&V effort across multiple teams and venues to provide full coverage of all necessary functionality, performance, and fault protection. First, it provides an overview of how the V&V campaign was subdivided among teams and venues and provides descriptions of the various hardware configurations used to support the testing. The Mars 2020 implementation of the plan incorporates many of the lessons learned from Mars Science Laboratory’s test campaign, and these value-added modifications are discussed here. Also included in this section is the system-level environmental testing approach used for mechanisms. Second, the paper describes the phased approach used by the teams to support new hardware and software deliveries to testbed and Systems I&T. In this approach the test campaign was built upon higher-level mechanism needs for performance, functionality, and safety at specific times in the campaign. Finally, the paper discusses lessons learned from the V&V campaign that should be applied to future large-scale motion control testing efforts.

Borne, Davis↗

NASA NTRS1987

A dual-processor multi-frequency implementation of the FINDS algorithm

This report presents a parallel processing implementation of the FINDS (Fault Inferring Nonlinear Detection System) algorithm on a dual processor configured target flight computer. First, a filter initialization scheme is presented which allows the no-fail filter (NFF) states to be initialized using the first iteration of the flight data. A modified failure isolation strategy, compatible with the new failure detection strategy reported earlier, is discussed and the performance of the new FDI algorithm is analyzed using flight recorded data from the NASA ATOPS B-737 aircraft in a Microwave Landing System (MLS) environment. The results show that low level MLS, IMU, and IAS sensor failures are detected and isolated instantaneously, while accelerometer and rate gyro failures continue to take comparatively longer to detect and isolate. The parallel implementation is accomplished by partitioning the FINDS algorithm into two parts: one based on the translational dynamics and the other based on the rotational kinematics. Finally, a multi-rate implementation of the algorithm is presented yielding significantly low execution times with acceptable estimation and FDI performance.

Godiwala, Pankaj M.↗

NASA NTRS2003

Columbia Accident Investigation Board Report. Volume Two

Volume II of the Report contains appendices that were cited in Volume I. The Columbia Accident Investigation Board produced many of these appendices as working papers during the investigation into the February 1, 2003 destruction of the Space Shuttle Columbia. Other appendices were produced by other organizations (mainly NASA) in support of the Board investigation. In the case of documents that have been published by others, they are included here in the interest of establishing a complete record, but often at less than full page size. Contents include: CAIB Technical Documents Cited in the Report: Reader's Guide to Volume II; Appendix D. a Supplement to the Report; Appendix D.b Corrections to Volume I of the Report; Appendix D.1 STS-107 Training Investigation; Appendix D.2 Payload Operations Checklist 3; Appendix D.3 Fault Tree Closure Summary; Appendix D.4 Fault Tree Elements - Not Closed; Appendix D.5 Space Weather Conditions; Appendix D.6 Payload and Payload Integration; Appendix D.7 Working Scenario; Appendix D.8 Debris Transport Analysis; Appendix D.9 Data Review and Timeline Reconstruction Report; Appendix D.10 Debris Recovery; Appendix D.11 STS-107 Columbia Reconstruction Report; Appendix D.12 Impact Modeling; Appendix D.13 STS-107 In-Flight Options Assessment; Appendix D.14 Orbiter Major Modification (OMM) Review; Appendix D.15 Maintenance, Material, and Management Inputs; Appendix D.16 Public Safety Analysis; Appendix D.17 MER Manager's Tiger Team Checklist; Appendix D.18 Past Reports Review; Appendix D.19 Qualification and Interpretation of Sensor Data from STS-107; Appendix D.20 Bolt Catcher Debris Analysis.

CAIB (COLUMBIA ACCIDENT INVESTIGATION BOARD)↗

NASA NTRS2005

Design Methods and Practices for Fault Prevention and Management in Spacecraft

Integrated Systems Health Management (ISHM) is intended to become a critical capability for all space, lunar and planetary exploration vehicles and systems at NASA. Monitoring and managing the health state of diverse components, subsystems, and systems is a difficult task that will become more challenging when implemented for long-term, evolving deployments. A key technical challenge will be to ensure that the ISHM technologies are reliable, effective, and low cost, resulting in turn in safe, reliable, and affordable missions. To ensure safety and reliability, ISHM functionality, decisions and knowledge have to be incorporated into the product lifecycle as early as possible, and ISHM must be considered as an essential element of models developed and used in various stages during system design. During early stage design, many decisions and tasks are still open, including sensor and measurement point selection, modeling and model-checking, diagnosis, signature and data fusion schemes, presenting the best opportunity to catch and prevent potential failures and anomalies in a cost-effective way. Using appropriate formal methods during early design, the design teams can systematically explore risks without committing to design decisions too early. However, the nature of ISHM knowledge and data is detailed, relying on high-fidelity, detailed models, whereas the earlier stages of the product lifecycle utilize low-fidelity, high-level models of systems and their functionality. We currently lack the tools and processes necessary for integrating ISHM into the vehicle system/subsystem design. As a result, most existing ISHM-like technologies are retrofits that were done after the system design was completed. It is very expensive, and sometimes futile, to retrofit a system health management capability into existing systems. Last-minute retrofits result in unreliable systems, ineffective solutions, and excessive costs (e.g., Space Shuttle TPS monitoring which was considered only after 110 flights and the Columbia disaster). High false alarm or false negative rates due to substandard implementations hurt the credibility of the ISHM discipline. This paper presents an overview of the current state of ISHM design,and a review of formal design methods to make recommendations about possible approaches to enable the ISHM capabilities to be designed-in at the system-level, from the very beginning of the vehicle design process.

Tumer, Irem Y.↗

NASA NTRS2012

Modular, Autonomous Command and Data Handling Software with Built-In Simulation and Test

The spacecraft system that plays the greatest role throughout the program lifecycle is the Command and Data Handling System (C&DH), along with the associated algorithms and software. The C&DH takes on this role as cost driver because it is the brains of the spacecraft and is the element of the system that is primarily responsible for the integration and interoperability of all spacecraft subsystems. During design and development, many activities associated with mission design, system engineering, and subsystem development result in products that are directly supported by the C&DH, such as interfaces, algorithms, flight software (FSW), and parameter sets. A modular system architecture has been developed that provides a means for rapid spacecraft assembly, test, and integration. This modular C&DH software architecture, which can be targeted and adapted to a wide variety of spacecraft architectures, payloads, and mission requirements, eliminates the current practice of rewriting the spacecraft software and test environment for every mission. This software allows missionspecific software and algorithms to be rapidly integrated and tested, significantly decreasing time involved in the software development cycle. Additionally, the FSW includes an Onboard Dynamic Simulation System (ODySSy) that allows the C&DH software to support rapid integration and test. With this solution, the C&DH software capabilities will encompass all phases of the spacecraft lifecycle. ODySSy is an on-board simulation capability built directly into the FSW that provides dynamic built-in test capabilities as soon as the FSW image is loaded onto the processor. It includes a six-degrees- of-freedom, high-fidelity simulation that allows complete closed-loop and hardware-in-the-loop testing of a spacecraft in a ground processing environment without any additional external stimuli. ODySSy can intercept and modify sensor inputs using mathematical sensor models, and can intercept and respond to actuator commands. ODySSy integration is unique in that it allows testing of actual mission sequences on the flight vehicle while the spacecraft is in various stages of assembly, test, and launch operations all without any external support equipment or simulators. The ODySSy component of the FSW significantly decreases the time required for integration and test by providing an automated, standardized, and modular approach to integrated avionics and component interface and functional verification. ODySSy further provides the capability for on-orbit support in the form of autonomous mission planning and fault protection.

Cuseo, John↗

NASA NTRS2015

Mission Adaptive UAS Platform for Earth Science Resource Assessment

NASA Ames Research Center has led a number of important Earth science remote sensing missions including several directed at the assessment of natural resources. A key asset for accessing high risk airspace has been the 180 kg class SIERRA UAS platform, providing mission durations of up to 8 hrs at altitudes up to 3 km. Recent improvements to this mission capability are embodied in the incipient SIERRA-B variant. Two resource mapping problems having unusual mission characteristics requiring a mission adaptive capability are explored here. One example involves the requirement for careful control over solar angle geometry for passive reflectance measurements. This challenges the management of resources in the coastal ocean where solar angle combines with sea state to produce surface glint that can obscure the ocean color signal. Furthermore, as for all scanning imager applications, the primary flight control priority to fly the UAS directly to the next waypoint should compromise with the requirement to minimize roll and crab effects in the imagery. A second example involves the mapping of natural resources in the Earth's crust using precision magnetometry. In this case the vehicle flight path must be oriented to optimize magnetic flux gradients over a spatial domain having continually emerging features, while optimizing the efficiency of the spatial mapping task. These requirements were highlighted in several recent Earth Science missions including the October 2013 OCEANIA mission directed at improving the capability for hyperspectral reflectance measurements in the coastal ocean, and the Surprise Valley Mission directed at mapping sub-surface mineral composition and faults, using high-sensitivity magentometry. This paper reports the development of specific aircraft control approaches to incorporate the unusual and demanding requirements to manage solar angle, aircraft attitude and flight path orientation, and efficient (directly geo-rectified) surface and sub-surface mapping, including the near-time optimization of these sometimes conflicting requirements. *

Flight Control↗

NASA NTRS1988

Feasibility of using GPS measurements for OMV attitude update

This paper presents the results of a feasibility study to determine whether the measurements from GPS satellites can be used to estimate the OMV attitude to an accuracy comparable to the onboard sun sensors, i.e., better than 0.5 degree in each axis. The results documented in this paper demonstrate that OMV attitude can be estimated to an accuracy of 0.1 - 0.5 degree in each axis by processing GPS measurements in an onboard integrated, 17-state GPS/inertial navigation filter. The result is particularly significant for missions of short duration burns where accurate attitude information is needed to minimize guidance and control errors. It is shown that the GPS attitude technique described in this paper can be easily implemented in the current OMV navigation system design. Results reported in this paper are expected to support the goal of developing a fault-tolerant guidance, navigation, and control system offering an improved total navigation performance for the OMV.

Upadhyay, Triveni N.↗

NASA NTRS2011

NEXUS Scalable and Distributed Next-Generation Avionics Bus for Space Missions

A paper discusses NEXUS, a common, next-generation avionics interconnect that is transparently compatible with wired, fiber-optic, and RF physical layers; provides a flexible, scalable, packet switched topology; is fault-tolerant with sub-microsecond detection/recovery latency; has scalable bandwidth from 1 Kbps to 10 Gbps; has guaranteed real-time determinism with sub-microsecond latency/jitter; has built-in testability; features low power consumption (< 100 mW per Gbps); is lightweight with about a 5,000-logic-gate footprint; and is implemented in a small Bus Interface Unit (BIU) with reconfigurable back-end providing interface to legacy subsystems. NEXUS enhances a commercial interconnect standard, Serial RapidIO, to meet avionics interconnect requirements without breaking the standard. This unified interconnect technology can be used to meet performance, power, size, and reliability requirements of all ranges of equipment, sensors, and actuators at chip-to-chip, board-to-board, or box-to-box boundary. Early results from in-house modeling activity of Serial RapidIO using VisualSim indicate that the use of a switched, high-performance avionics network will provide a quantum leap in spacecraft onboard science and autonomy capability for science and exploration missions.

He, Yutao↗

NASA NTRS2022

Electrical Ground Support Equipment for the Sampling Caching System of the Mars 2020 Rover

In this work we describe in detail the architecture, design, testing and operation of the Electrical Ground Support Equipment (EGSE) “Blue Box” used to test and validate the Sampling Caching System (SCS) of the Mars 2020 Perseverance rover. The Blue Box architecture is centered around COTS motor controllers and COTS input-output modules communicating over an EtherCAT bus. A custom, low-level safety subsystem ensures no harm can be done to the flight articles. The modular architecture of the EGSE reduces cost and complexity while expediting assembly time. The Blue Box drives the 19 actuators of the SCS which span the main robotic arm, the corer system, the internal sample handling arm, the sample tube sealing system and the gas dust removal tool; mimicking the Rover Motor Control Assembly (RMCA). Due to the limited availability of RMCA’s, the EGSE enabled and performed the bulk of testing activities for SCS. The majority of the SCS actuators are composed of a 3-phase DC brushless motors, hall sensors for commutation, dual resolvers for output angular measurement, brakes, heaters and platinum thermistors. Additionally, the EGSE read 12 strain gauges forming part of a force torque sensor, and switches used for external positioning references. Over the 3-year span of the V&V campaign for the SCS, over 32 EGSE systems were built, tested and deployed to test venues at JPL and externally. The EGSE tested several families of the SCS subsystem, ranging from engineering units, life test units and two flight units. Test venues that this EGSE supported included lab benches, ultra-clean cleanrooms, ATLO facilities, and thermal vacuum chambers. Together with the test software systems, SSDEV and SSDEV-ECAT, the Blue Box EGSE enabled the team to efficiently test flight hardware and flight software together. We go over the safety features and fault management techniques employed to protect flight hardware. The effects of the long, 50-feet, EGSE harnesses on motor performance, EMI, electrical noise, and motor control performance are explained. Mitigations to these unwanted effects, including shielding strategy and inductance compensation, are summarized. We go over an excerpt of notable anomalies that this EGSE suffered through its operation, along with investigations and resolutions. Lessons learned, areas of improvement as part of future work, and recommendations for future implementations for similar EGSE’s, are shared.

Levine, Dan↗