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Use of probabilistic design methods for NASA applications

This paper presents a reliability evaluation process designed to improve the reliability of advanced launch systems. The work performed includes the development of a reliability prediction methodology to be used in the design phase of the Space Transportation Main Engine (STME). This includes prediction techniques which use historical data bases as well as deterministic and probabilistic engineering models for predicting design reliability. In summary, this paper describes a probabilistic design approach for the next-generation liquid rocket engine, the STME.

Safie, Fayssal M.

Commercial Parts Technology Qualification Processes

Many high-reliability systems, including space systems, use selected commercial parts (including Plastic Encapsulated Microelectronics or PEMs) for unique functionality, small size, low weight, high mechanical shock resistance, and other factors. Predominantly this usage is subjected to certain 100% tests (typically called screens) and certain destructive tests usually (but not always) performed on the flight lot (typically called qualification tests). Frequently used approaches include those documented in EEE-INST-002 and JPL DocID62212 (which are sometimes modified by the particular aerospace space systems manufacturer). In this study, approaches from these documents and several space systems manufacturers are compared to approaches from a launch systems manufacturer (SpaceX), an implantable medical electronics manufacturer (Medtronics), and a high-reliability transport system process (automotive systems). In the conclusions section, these processes are outlined for all of these cases and presented in tabular form. Then some simple comparisons are made. In this introduction section, the PEM technology qualification process is described, as documented in EEE-INST-002 (written by the Goddard Space Flight Center, GSFC), as well as the somewhat modified approach employed at the Jet Propulsion Laboratory (JPL). Approaches used at several major NASA contractors are also described

Cooper, Mark S.

Thirsty Walls: A New Paradigm for Air Revitalization in Life Support

This Phase I project Summary will be formatted as a series of summary statements, with additional comments. The summary statements are intended to focus on the most significant findings and discoveries – things that the project team knows now, but we didn’t know at the beginning of the project: 1) Direct Contact Between Gases is an ECLS (Environmental Control and Life Support) System enabling capability; 2) CO2 capture using liquid sorbents in microgravity is feasible; 3) There are other ways to contact gases and liquids – but thin film capillary techniques are new, exciting, and have amazing potential; 4) ECLS system reliability is the key to exploration missions – the key to reliability is having system attributes that favor reliability; 5) The processes with favorable reliability attributes tend to be biological; 6) The single greatest impact on launch mass of an ECLS system is water. The best way to enable biological water processing is to develop a capillary based method of urine capture that doesn’t use pretreat chemicals; 7) There is good, promising, forward design and development work – but no fundamental “show stoppers” – to develop a thin film liquid sorbent CO2 capture system; 8) The most capable Ionic Liquids are not presently feasible, but other chemically active liquids can be used to make an effective thin film CO2 capture device; 9) The C9 reduced gravity flight showed feasibility – and taught us about flow instability issues; 10) Capillary fluid management has ECLS system wide implications.

CO2

Brazing process using'al-Si filler alloy reliably bonds aluminum parts

Brazing process employs an aluminum-silicon filler alloy for diffusion bonding of aluminum parts in a vacuum or inert gas atmosphere. This process is carried out at temperatures substantially below those required in conventional process and produces bonds of greater strength and reliability.

Beuyukian, C. S.

The process group approach to reliable distributed computing

The difficulty of developing reliable distribution software is an impediment to applying distributed computing technology in many settings. Experience with the ISIS system suggests that a structured approach based on virtually synchronous process groups yields systems that are substantially easier to develop, exploit sophisticated forms of cooperative computation, and achieve high reliability. Six years of research on ISIS, describing the model, its implementation challenges, and the types of applications to which ISIS has been applied are reviewed.

Birman, Kenneth P.

The process group approach to reliable distributed computing

The difficulty of developing reliable distributed software is an impediment to applying distributed computing technology in many settings. Experience with the ISIS system suggests that a structured approach based on virtually synchronous process groups yields systems which are substantially easier to develop, fault-tolerance, and self-managing. Six years of research on ISIS are reviewed, describing the model, the types of applications to which ISIS was applied, and some of the reasoning that underlies a recent effort to redesign and reimplement ISIS as a much smaller, lightweight system.

Birman, Kenneth P.

Verification of Triple Modular Redundancy (TMR) Insertion for Reliable and Trusted Systems

We propose a method for TMR insertion verification that satisfies the process for reliable and trusted systems. If a system is expected to be protected using TMR, improper insertion can jeopardize the reliability and security of the system. Due to the complexity of the verification process, there are currently no available techniques that can provide complete and reliable confirmation of TMR insertion. This manuscript addresses the challenge of confirming that TMR has been inserted without corruption of functionality and with correct application of the expected TMR topology. The proposed verification method combines the usage of existing formal analysis tools with a novel search-detect-and-verify tool. Field programmable gate array (FPGA),Triple Modular Redundancy (TMR),Verification, Trust, Reliability,

Trust

Reliable and Efficient Parallel Processing Algorithms and Architectures for Modern Signal Processing

Least-squares (LS) estimations and spectral decomposition algorithms constitute the heart of modern signal processing and communication problems. Implementations of recursive LS and spectral decomposition algorithms onto parallel processing architectures such as systolic arrays with efficient fault-tolerant schemes are the major concerns of this dissertation. There are four major results in this dissertation. First, we propose the systolic block Householder transformation with application to the recursive least-squares minimization. It is successfully implemented on a systolic array with a two-level pipelined implementation at the vector level as well as at the word level. Second, a real-time algorithm-based concurrent error detection scheme based on the residual method is proposed for the QRD RLS systolic array. The fault diagnosis, order degraded reconfiguration, and performance analysis are also considered. Third, the dynamic range, stability, error detection capability under finite-precision implementation, order degraded performance, and residual estimation under faulty situations for the QRD RLS systolic array are studied in details. Finally, we propose the use of multi-phase systolic algorithms for spectral decomposition based on the QR algorithm. Two systolic architectures, one based on triangular array and another based on rectangular array, are presented for the multiphase operations with fault-tolerant considerations. Eigenvectors and singular vectors can be easily obtained by using the multi-pase operations. Performance issues are also considered.

Liu, Kuojuey Ray

Space Shuttle Propulsion System Reliability

This session includes the following sessions: (1) External Tank (ET) System Reliability and Lessons, (2) Space Shuttle Main Engine (SSME), Reliability Validated by a Million Seconds of Testing, (3) Reusable Solid Rocket Motor (RSRM) Reliability via Process Control, and (4) Solid Rocket Booster (SRB) Reliability via Acceptance and Testing.

Welzyn, Ken

New Directions in Space Operations Services in Support of Interplanetary Exploration

To gain access to the necessary operational processes and data in support of NASA's Lunar/Mars Exploration Initiative, new services, adequate levels of computing cycles and access to myriad forms of data must be provided to onboard spacecraft and ground based personnel/systems (earth, lunar and Martian) to enable interplanetary exploration by humans. These systems, cycles and access to vast amounts of development, test and operational data will be required to provide a new level of services not currently available to existing spacecraft, on board crews and other operational personnel. Although current voice, video and data systems in support of current space based operations has been adequate, new highly reliable and autonomous processes and services will be necessary for future space exploration activities. These services will range from the more mundane voice in LEO to voice in interplanetary travel which because of the high latencies will require new voice processes and standards. New services, like component failure predictions based on data mining of significant quantities of data, located at disparate locations, will be required. 3D or holographic representation of onboard components, systems or family members will greatly improve maintenance, operations and service restoration not to mention crew morale. Current operational systems and standards, like the Internet Protocol, will not able to provide the level of service required end to end from an end point on the Martian surface like a scientific instrument to a researcher at a university. Ground operations whether earth, lunar or Martian and in flight operations to the moon and especially to Mars will require significant autonomy that will require access to highly reliable processing capabilities, data storage based on network storage technologies. Significant processing cycles will be needed onboard but could be borrowed from other locations either ground based or onboard other spacecraft. Reliability will be a key factor with onboard and distributed backup processing an absolutely necessary requirement. Current cluster processing/Grid technologies may provide the basis for providing these services. An overview of existing services, future services that will be required and the technologies and standards required to be developed will be presented. The purpose of this paper will be to initiate a technological roadmap, albeit at a high level, of current voice, video, data and network technologies and standards (which show promise for adaptation or evolution) to what technologies and standards need to be redefined, adjusted or areas where new ones require development. The roadmap should begin the differentiation between non manned and manned processes/services where applicable. The paper will be based in part on the activities of the CCSDS Monitor and Control working group which is beginning the process of standardization of the these processes. Another element of the paper will be based on an analysis of current technologies supporting space flight processes and services at JSC, MSFC, GSFC and to a lesser extent at KSC. Work being accomplished in areas such as Grid computing, data mining and network storage at ARC, IBM and the University of Alabama at Huntsville will be researched and analyzed.

Bradford, Robert N.

Integrated Logistics Support Analysis of the International Space Station Alpha: An Overview of the Maintenance Time Dependent Parameter Prediction Methods Enhancement

The objective of this publication is to introduce the enhancement methods for the overall reliability and maintainability methods of assessment on the International Space Station. It is essential that the process to predict the values of the maintenance time dependent variable parameters such as mean time between failure (MTBF) over time do not in themselves generate uncontrolled deviation in the results of the ILS analysis such as life cycle costs, spares calculation, etc. Furthermore, the very acute problems of micrometeorite, Cosmic rays, flares, atomic oxygen, ionization effects, orbital plumes and all the other factors that differentiate maintainable space operations from non-maintainable space operations and/or ground operations must be accounted for. Therefore, these parameters need be subjected to a special and complex process. Since reliability and maintainability strongly depend on the operating conditions that are encountered during the entire life of the International Space Station, it is important that such conditions are accurately identified at the beginning of the logistics support requirements process. Environmental conditions which exert a strong influence on International Space Station will be discussed in this report. Concurrent (combined) space environments may be more detrimental to the reliability and maintainability of the International Space Station than the effects of a single environment. In characterizing the logistics support requirements process, the developed design/test criteria must consider both the single and/or combined environments in anticipation of providing hardware capability to withstand the hazards of the International Space Station profile. The effects of the combined environments (typical) in a matrix relationship on the International Space Station will be shown. The combinations of the environments where the total effect is more damaging than the cumulative effects of the environments acting singly, may include a combination such as temperature, humidity, altitude, shock, and vibration while an item is being transported. The item's acceptance to its end-of-life sequence must be examined for these effects.

Sepehry-Fard, F.

Design for Reliability (DfR) in Space Life Support

The engineering process of Design for Reliability (DfR) is well established in the automotive and aerospace industries. DfR should be useful in the future development of space life support systems. DfR is a sequence of tasks that develop system requirements and plan reliability analysis and testing. First and fundamentally, the reliability requirement is defined. Next the system reliability model is developed, often using a reliability block diagram. The overall system reliability requirement is allocated to the subsystems and an estimate of the attainable reliability is made. This expected reliability can be improved by simplifying the design by removing components or by replacing less reliable components. Improving reliability can require difficult compromises, such as reducing performance requirements, increasing budget, or extending testing. The actual system reliability can be determined only by testing, which should continue long enough to provide the required confidence in the measured value. New systems often have unexpected design errors that cause failures in early testing. The usual reliability improvement process of testing, finding the failure modes, and redesigning to remove them reduces the failure rate and is referred to as “reliability growth.” After redesign has been completed, the system should be further tested to determine the actual achieved reliability more accurately. If the final system failure rate is too high, redundant systems can be used to improve overall operational reliability. Adding redundancy simply to increase the one- or two-fault tolerance metric may sometimes reduce reliability. Reliability can be improved in three ways: redesigning the system to include more reliable subsystems and components, reliability growth testing and failure mode removal, and by using parallel redundant systems. DfR should combine these approaches to achieve the required reliability while managing performance, cost, and schedule.

Reliability

Design for Reliability (DfR) in Space Life Support

The engineering process of Design for Reliability (DfR) is well established in the automotive and aerospace industries. DfR should be useful in the future development of space life support systems. DfR is a sequence of tasks that develop system requirements and plan reliability analysis and testing. First and fundamentally, the reliability requirement is defined. Next the system reliability model is developed, often using a reliability block diagram. The overall system reliability requirement is allocated to the subsystems and an estimate of the attainable reliability is made. This expected reliability can be improved by simplifying the design by removing components or by replacing less reliable components. Improving reliability can require difficult compromises, such as reducing performance requirements, increasing budget, or extending testing. The actual system reliability can be determined only by testing, which should continue long enough to provide the required confidence in the measured value. New systems often have unexpected design errors that cause failures in early testing. The usual reliability improvement process of testing, finding the failure modes, and redesigning to remove them reduces the failure rate and is referred to as “reliability growth.” After redesign has been completed, the system should be further tested to determine the actual achieved reliability more accurately. If the final system failure rate is too high, redundant systems can be used to improve overall operational reliability. Adding redundancy simply to increase the one- or two-fault tolerance metric may sometimes reduce reliability. Reliability can be improved in three ways: redesigning the system to include more reliable subsystems and components, reliability growth testing and failure mode removal, and by using parallel redundant systems. DfR should combine these approaches to achieve the required reliability while managing performance, cost, and schedule.

Reliability

An error bound for instantaneous coverage

An error bound is derived for a reliability model approximation method. The approximation method is appropriate for the semi-Markov models of reconfigurable systems that are designed to achieve extremely high reliability. The semi-Markov models of these system are complex, and a significant amount of their complexity arises from the detailed descriptions of the reconfiguration processes. The reliability model approximation method consists of replacing a detailed description of a reconfiguration process with the probabilities of the possible outcomes of the reconfiguration process. These probabilities are included in the model as instantaneous jumps from the fault-occurrence state. Since little time is spent in the reconfiguration states, instantaneous jumps are a close approximation to the original model. This approximation procedure is shown to produce an overestimation for the probability of system failure, and an error bound is derived for this overestimation.

White, Allan L.

Supersonic Retropulsion Surface Preparation of Carbon Fiber Reinforced Epoxy Composites for Adhesive Bonding

Surface preparation is widely recognized as a key step to producing robust and predictable bonds in a precise and reproducible manner. Standard surface preparation techniques, including grit blasting, manual abrasion, and peel ply, can lack precision and reproducibility, which can lead to variation in surface properties and subsequent bonding performance. The use of a laser to ablate composite surface resin can provide an efficient, precise, and reproducible means of preparing composite surfaces for adhesive bonding. Advantages include elimination of physical waste (i.e., grit media and sacrificial peel ply layers that ultimately require disposal), reduction in process variability due to increased precision (e.g. increased reproducibility), and automation of surface preparation, all of which improve reliability and process control. This paper describes a Nd:YAG laser surface preparation technique for composite substrates and the mechanical performance and failure modes of bonded laminates thus prepared. Additionally, bonded specimens were aged in a hot, wet environment for approximately one year and subsequently mechanically tested. The results of a one year hygrothermal aging study will be presented.

Palmieri, Frank L.

Reliability Methods for Shield Design Process

Providing protection against the hazards of space radiation is a major challenge to the exploration and development of space. The great cost of added radiation shielding is a potential limiting factor in deep space operations. In this enabling technology, we have developed methods for optimized shield design over multi-segmented missions involving multiple work and living areas in the transport and duty phase of space missions. The total shield mass over all pieces of equipment and habitats is optimized subject to career dose and dose rate constraints. An important component of this technology is the estimation of two most commonly identified uncertainties in radiation shield design, the shielding properties of materials used and the understanding of the biological response of the astronaut to the radiation leaking through the materials into the living space. The largest uncertainty, of course, is in the biological response to especially high charge and energy (HZE) ions of the galactic cosmic rays. These uncertainties are blended with the optimization design procedure to formulate reliability-based methods for shield design processes. The details of the methods will be discussed.

Tripathi, R. K.

James Webb Space Telescope - L2 Communications for Science Data Processing

JWST is the first NASA mission at the second Lagrange point (L2) to identify the need for data rates higher than 10 megabits per second (Mbps). JWST will produce approximately 235 Gigabits of science data every day that will be downlinked to the Deep Space Network (DSN). To get the data rates desired required moving away from X-band frequencies to Ka-band frequencies. To accomplish this transition, the DSN is upgrading its infrastructure. This new range of frequencies are becoming the new standard for high data rate science missions at L2. With the new frequency range, the issues of alternatives antenna deployment, off nominal scenarios, NASA implementation of the Ka-band 26 GHz, and navigation requirements will be discussed in this paper. JWST is also using Consultative Committee for Space Data Systems (CCSDS) standard process for reliable file transfer using CCSDS File Delivery Protocol (CFDP). For JWST the use of the CFDP protocol provides level zero processing at the DSN site. This paper will address NASA implementations of Ground Stations in support of Ka-band 26 GHz and lesson learned from implementing a file base (CFDP) protocol operational system.

Johns, Alan