Gearing up for 1988
This video explains all engineering efforts to ensure safety and reliability for the next Shuttle mission, STS-26.
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Results for “Reliability Engineering”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Aerospace Safety Advisory Panel
The Aerospace Safety Advisory Panel (ASAP) provided oversight on the safety aspects of many NASA programs. In addition, ASAP undertook three special studies. At the request of the Administrator, the panel assessed the requirements for an assured crew return vehicle (ACRV) for the space station and reviewed the organization of the safety and mission quality function within NASA. At the behest of Congress, the panel formed an independent, ad hoc working group to examine the safety and reliability of the space shuttle main engine. Section 2 presents findings and recommendations. Section 3 consists of information in support of these findings and recommendations. Appendices A, B, C, and D, respectively, cover the panel membership, the NASA response to the findings and recommendations in the March 1992 report, a chronology of the panel's activities during the reporting period, and the entire ACRV study report.
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Rapid Modeling and Analysis Tools: Evolution, Status, Needs and Directions
Advanced aerospace systems are becoming increasingly more complex, and customers are demanding lower cost, higher performance, and high reliability. Increased demands are placed on the design engineers to collaborate and integrate design needs and objectives early in the design process to minimize risks that may occur later in the design development stage. High performance systems require better understanding of system sensitivities much earlier in the design process to meet these goals. The knowledge, skills, intuition, and experience of an individual design engineer will need to be extended significantly for the next generation of aerospace system designs. Then a collaborative effort involving the designer, rapid and reliable analysis tools and virtual experts will result in advanced aerospace systems that are safe, reliable, and efficient. This paper discusses the evolution, status, needs and directions for rapid modeling and analysis tools for structural analysis. First, the evolution of computerized design and analysis tools is briefly described. Next, the status of representative design and analysis tools is described along with a brief statement on their functionality. Then technology advancements to achieve rapid modeling and analysis are identified. Finally, potential future directions including possible prototype configurations are proposed.
Knight, Norman F., Jr.↗
Aircraft Controls
CARSRA, a computer program supplied by COSMIC (Computer Software Management and Information Center), enables Hamilton Standard to predict the reliability of electronic systems for jet engines. The flight control is fully automatic. With CARSRA, engineers can study a proposed design, predict its operation, and make necessary design modifications. The program is accurate and flexible, and Hamilton Standard has developed a more advanced program based on the COSMIC software.
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A software measurement and fault modeling technique
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fault detection software engineering technology so↗
Propulsion Controls and Diagnostics Research at NASA Glenn Research Center
With the increased emphasis on aircraft safety, enhanced performance and affordability, and the need to reduce the environmental impact of aircraft, there are many new challenges being faced by the designers of aircraft propulsion systems. Also the propulsion systems required to enable the National Aeronautics and Space Administration (NASA) Vision for Space Exploration in an affordable manner will need to have high reliability, safety and autonomous operation capability. The Controls and Dynamics Branch (CDB) at NASA Glenn Research Center (GRC) in Cleveland, Ohio, is leading and participating in various projects in partnership with other organizations within GRC and across NASA, the U.S. aerospace industry, and academia to develop advanced controls and health management technologies that will help meet these challenges through the concept of Intelligent Propulsion Systems. This paper describes the current activities of the CDB under the NASA Aeronautics Research and Exploration Systems Missions. The programmatic structure of the CDB activities is described along with a brief overview of each of the CDB tasks including research objectives, technical challenges, and recent accomplishments. These tasks include active control of propulsion system components, intelligent propulsion diagnostics and control for reliable fault identification and accommodation, distributed engine control, and investigations into unsteady propulsion systems.
Garg, Sanjay↗
Intelligent Engine Systems: Thermal Management and Advanced Cooling
The objective is to provide turbine-cooling technologies to meet Propulsion 21 goals related to engine fuel burn, emissions, safety, and reliability. Specifically, the GE Aviation (GEA) Advanced Turbine Cooling and Thermal Management program seeks to develop advanced cooling and flow distribution methods for HP turbines, while achieving a substantial reduction in total cooling flow and assuring acceptable turbine component safety and reliability. Enhanced cooling techniques, such as fluidic devices, controlled-vortex cooling, and directed impingement jets, offer the opportunity to incorporate both active and passive schemes. Coolant heat transfer enhancement also can be achieved from advanced designs that incorporate multi-disciplinary optimization of external film and internal cooling passage geometry.
Bergholz, Robert↗
Propulsion Controls and Diagnostics Research in Support of NASA Aeronautics and Exploration Mission Programs
The Controls and Dynamics Branch (CDB) at National Aeronautics and Space Administration (NASA) Glenn Research Center (GRC) in Cleveland, Ohio, is leading and participating in various projects in partnership with other organizations within GRC and across NASA, the U.S. aerospace industry, and academia to develop advanced propulsion controls and diagnostics technologies that will help meet the challenging goals of NASA programs under the Aeronautics Research and Exploration Systems Missions. This paper provides a brief overview of the various CDB tasks in support of the NASA programs. The programmatic structure of the CDB activities is described along with a brief overview of each of the CDB tasks including research objectives, technical challenges, and recent accomplishments. These tasks include active control of propulsion system components, intelligent propulsion diagnostics and control for reliable fault identification and accommodation, distributed engine control, and investigations into unsteady propulsion systems.
Garg, Sanjay↗
Trades Between Opposition and Conjunction Class Trajectories for Early Human Missions to Mars
Candidate human missions to Mars, including NASA's Design Reference Architecture 5.0, have focused on conjunction-class missions with long crewed durations and minimum energy trajectories to reduce total propellant requirements and total launch mass. However, in order to progressively reduce risk and gain experience in interplanetary mission operations, it may be desirable that initial human missions to Mars, whether to the surface or to Mars orbit, have shorter total crewed durations and minimal stay times at the destination. Opposition-class missions require larger total energy requirements relative to conjunction-class missions but offer the potential for much shorter mission durations, potentially reducing risk and overall systems performance requirements. This paper will present a detailed comparison of conjunction-class and opposition-class human missions to Mars vicinity with a focus on how such missions could be integrated into the initial phases of a Mars exploration campaign. The paper will present the results of a trade study that integrates trajectory/propellant analysis, element design, logistics and sparing analysis, and risk assessment to produce a comprehensive comparison of opposition and conjunction exploration mission constructs. Included in the trade study is an assessment of the risk to the crew and the trade offs between the mission duration and element, logistics, and spares mass. The analysis of the mission trade space was conducted using four simulation and analysis tools developed by NASA. Trajectory analyses for Mars destination missions were conducted using VISITOR (Versatile ImpulSive Interplanetary Trajectory OptimizeR), an in-house tool developed by NASA Langley Research Center. Architecture elements were evaluated using EXploration Architecture Model for IN-space and Earth-to-orbit (EXAMINE), a parametric modeling tool that generates exploration architectures through an integrated systems model. Logistics analysis was conducted using NASA's Human Exploration Logistics Model (HELM), and sparing allocation predictions were generated via the Exploration Maintainability Analysis Tool (EMAT), which is a probabilistic simulation engine that evaluates trades in spacecraft reliability and sparing requirements based on spacecraft system maintainability and reparability.
Mattfeld, Bryan↗
Integrated Pressure-Fed Liquid Oxygen / Methane Propulsion Systems - Morpheus Experience, MARE, and Future Applications
An integrated liquid oxygen (LOx) and methane propulsion system where common propellants are fed to the reaction control system and main engines offers advantages in performance, simplicity, reliability, and reusability. LOx/Methane provides new capabilities to use propellants that are manufactured on the Mars surface for ascent return and to integrate with power and life support systems. The clean burning, non-toxic, high vapor pressure propellants provide significant advantages for reliable ignition in a space vacuum, and for reliable safing or purging of a space-based vehicle. The NASA Advanced Exploration Systems (AES) Morpheus lander demonstrated many of these key attributes as it completed over 65 tests including 15 flights through 2014. Morpheus is a prototype of LOx/Methane propellant lander vehicle with a fully integrated propulsion system. The Morpheus lander flight demonstrations led to the proposal to use LOx/Methane for a Discovery class mission, named Moon Aging Regolith Experiment (MARE) to land an in-situ science payload for Southwest Research Institute on the Lunar surface. Lox/Methane is extensible to human spacecraft for many transportation elements of a Mars architecture. This paper discusses LOx/Methane propulsion systems in regards to trade studies, the Morpheus project experience, the MARE NAVIS (NASA Autonomous Vehicle for In-situ Science) lander, and future possible applications. The paper also discusses technology research and development needs for Lox/Methane propulsion systems.
Hurlbert, Eric↗
Practical Issues in Implementing Software Reliability Measurement
Many ways of estimating software systems' reliability, or reliability-related quantities, have been developed over the past several years.
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SUSAN Power/Propulsion System Emulation Test Predictions
The development of all-electric and hybrid-electric propulsion systems for transport aircraft presents an opportunity for new designs that can reduce fuel consumption and emissions from commercial aviation while enabling safer and more reliable aircraft. The SUbsonic Single Aft eNgine (SUSAN) is a conceptual design for a single-aisle transport aircraft with a series/parallel partial-hybrid propulsion system that is being developed by NASA as a reference design for single-aisle transport with a high degree of electrification. The SUSAN aircraft incorporates multiple tightly coupled power, propulsion, and flight control systems. This coupling leads to challenges in the aircraft control design process, requiring a hierarchical and more coordinated control architecture. This presentation will summarize the plans for a Hardware-in-the-Loop (HIL) test performed in the Hybrid Propulsion Emulation Rig (HyPER) facility at NASA Glenn Research Center (GRC). During this test, a real-time reference model of the full-scale SUSAN powertrain and controllers will be run alongside a sub-scale electro-mechanical system representing a portion of the electrified components in the SUSAN hybrid powertrain. This test will allow the performance of the SUSAN controllers to be evaluated using real powertrain components and allows side-by-side comparison between the real and modeled subsystems. This presentation will summarize the full-scale system model, steps towards integration of representative hardware for future control testing, and predicted results.
Jonah J. Sachs-Wetstone↗
Evaluation of Feed-Through Polymer Tantalum Capacitors for Space Applications
In 2023 AVX developed a new technology of feed-through capacitors that can be used for high (up to GHz range) frequency signal filtering for FPGA, microswitches or micro-DC-DC converters as a replacement for the currently used MLCCs. This part is a Low Inductance Bulk Capacitor (LIBC). It has low ESR and insertion loss values and is manufactured using technology similar to chip polymer tantalum capacitors and have. The purpose of this work is to evaluate the design and performance of the parts using engineering samples from AVX, address potential reliability issues, and suggest screening and lot acceptance procedures necessary to use these capacitors in space projects.
Alexander Teverovsky↗
MSFC-TVC | TB-03: Derivation of Thrust Vector Control (TVC) Actuator-Force / Gimbal-Torque Transformation Matrix
Thrust vector control (TVC) systems for rocket engine propulsion traditionally use a simple linear relationship to convert between actuator forces and torques about the engine gimbal’s center-of-rotation (COR). As shown in Equation (1), the torque about the gimbal COR is proportional to the applied actuator force and the TVC moment arm (MA)—the perpendicular distance between the TVC actuator’s line-of-action (LOA) and the engine gimbal’s COR. While this fundamental relationship remains valid and accurate in a two-dimensional (2D), one-degree-of-freedom (1-DOF) context—particularly in its non-linear formulation as described in the ER63 Technical Bulletin TB-02 (Derivation of Thrust Vector Control (TVC) Engine-Gimbal / Actuator Moment-Arm Geometry)—it becomes limited when extended to three-dimensional (3D), two-degree-of-freedom (2-DOF) analyses. In 3D, out-of-plane angular displacements can arise, causing the gimbaled engine plane-of-motion to become non-coplanar with the respective actuator plane-of-motion. Such misalignments occur due to the rod-end (RE) and/or tail-stock (TE) mounting geometry of individual TVC actuators. These geometric complexities lead to inaccuracies in calculating engine torques and corresponding actuator forces if only the traditional TVC MA relationship is employed. For higher gimbal angular displacements (e.g., greater than 5 degrees), these inaccuracies become more pronounced, necessitating a more robust mathematical framework. This document presents a comprehensive 3D (2-DOF) derivation of a transformation matrix that accurately converts between gimbaled engine torques and TVC actuator forces. By incorporating the necessary geometric and rotational considerations, this new approach corrects the limitations of the traditional TVC MA method. Subsequent sections compare the newly formulated approach to the traditional method, demonstrating its enhanced accuracy and reliability for a broad range of gimbaled engine conditions.
Thrust Vector Control↗
Distributed Engine Control Empirical/Analytical Verification Tools
NASA's vision for an intelligent engine will be realized with the development of a truly distributed control system featuring highly reliable, modular, and dependable components capable of both surviving the harsh engine operating environment and decentralized functionality. A set of control system verification tools was developed and applied to a C-MAPSS40K engine model, and metrics were established to assess the stability and performance of these control systems on the same platform. A software tool was developed that allows designers to assemble easily a distributed control system in software and immediately assess the overall impacts of the system on the target (simulated) platform, allowing control system designers to converge rapidly on acceptable architectures with consideration to all required hardware elements. The software developed in this program will be installed on a distributed hardware-in-the-loop (DHIL) simulation tool to assist NASA and the Distributed Engine Control Working Group (DECWG) in integrating DCS (distributed engine control systems) components onto existing and next-generation engines.The distributed engine control simulator blockset for MATLAB/Simulink and hardware simulator provides the capability to simulate virtual subcomponents, as well as swap actual subcomponents for hardware-in-the-loop (HIL) analysis. Subcomponents can be the communication network, smart sensor or actuator nodes, or a centralized control system. The distributed engine control blockset for MATLAB/Simulink is a software development tool. The software includes an engine simulation, a communication network simulation, control algorithms, and analysis algorithms set up in a modular environment for rapid simulation of different network architectures; the hardware consists of an embedded device running parts of the CMAPSS engine simulator and controlled through Simulink. The distributed engine control simulation, evaluation, and analysis technology provides unique capabilities to study the effects of a given change to the control system in the context of the distributed paradigm. The simulation tool can support treatment of all components within the control system, both virtual and real; these include communication data network, smart sensor and actuator nodes, centralized control system (FADEC full authority digital engine control), and the aircraft engine itself. The DECsim tool can allow simulation-based prototyping of control laws, control architectures, and decentralization strategies before hardware is integrated into the system. With the configuration specified, the simulator allows a variety of key factors to be systematically assessed. Such factors include control system performance, reliability, weight, and bandwidth utilization.
DeCastro, Jonathan↗
Practical Applications of Cosmic Ray Science: Spacecraft, Aircraft, Ground-Based Computation and Control Systems, and Human Health and Safety
Three twentieth century technological developments, 1) high altitude commercial and military aircraft; 2) manned and unmanned spacecraft; and 3) increasingly complex and sensitive solid state micro-electronics systems, have driven an ongoing evolution of basic cosmic ray science into a set of practical engineering tools needed to design, test, and verify the safety and reliability of modern complex technological systems. The effects of primary cosmic ray particles and secondary particle showers produced by nuclear reactions with the atmosphere, can determine the design and verification processes (as well as the total dollar cost) for manned and unmanned spacecraft avionics systems. Similar considerations apply to commercial and military aircraft operating at high latitudes and altitudes near the atmospheric Pfotzer maximum. Even ground based computational and controls systems can be negatively affected by secondary particle showers at the Earth s surface, especially if the net target area of the sensitive electronic system components is large. Finally, accumulation of both primary cosmic ray and secondary cosmic ray induced particle shower radiation dose is an important health and safety consideration for commercial or military air crews operating at high altitude/latitude and is also one of the most important factors presently limiting manned space flight operations beyond low-Earth orbit (LEO). In this paper we review the discovery of cosmic ray effects on the performance and reliability of microelectronic systems as well as human health and the development of the engineering and health science tools used to evaluate and mitigate cosmic ray effects in ground-based atmospheric flight, and space flight environments. Ground test methods applied to microelectronic components and systems are used in combinations with radiation transport and reaction codes to predict the performance of microelectronic systems in their operating environments. Similar radiation transport codes are used to evaluate possible human health effects of cosmic ray exposure, however, the health effects are based on worst-case analysis and extrapolation of a very limited human exposure data base combined with some limited experimental animal data. Finally, the limitations on human space operations beyond low-Earth orbit imposed by long term exposure to galactic cosmic rays are discussed.
Atwell, William↗
Stirling engine application study
A range of potential applications for Stirling engines in the power range from 0.5 to 5000 hp is surveyed. Over one hundred such engine applications are grouped into a small number of classes (10), with the application in each class having a high degree of commonality in technical performance and cost requirements. A review of conventional engines (usually spark ignition or Diesel) was then undertaken to determine the degree to which commercial engine practice now serves the needs of the application classes and to detemine the nature of the competition faced by a new engine system. In each application class the Stirling engine was compared to the conventional engines, assuming that objectives of ongoing Stirling engine development programs are met. This ranking process indicated that Stirling engines showed potential for use in all application classes except very light duty applications (lawn mowers, etc.). However, this potential is contingent on demonstrating much greater operating life and reliability than has been demonstrated to date by developmental Stirling engine systems. This implies that future program initiatives in developing Stirling engine systems should give more emphasis to life and reliability issues than has been the case in ongoing programs.
Teagan, W. P.↗
The Space Shuttle Main Engine and its maintenance features
The Space Shuttle Main Engine (SSME) is a reusable, high-performance rocket engine being developed to satisfy the performance, life, reliability, and operational requirements of the Space Shuttle Orbiter. The design includes simple, low-cost maintenance features resulting from a viable maintainability program dedicated to minimizing engine cost per flight.
Wheelock, V. J.↗