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DOE OSTI2017

Design Features of the Neutral Particle Diagnostic System for the ITER Tokamak

The control of the deuterium–tritium (DT) fuel isotopic ratio has to ensure the best performance of the ITER thermonuclear fusion reactor. The diagnostic system described in this paper allows the measurement of this ratio analyzing the hydrogen isotope fluxes (performing neutral particle analysis (NPA)). The development and supply of the NPA diagnostics for ITER was delegated to the Russian Federation. The diagnostics is being developed at the Ioffe Institute. The system consists of two analyzers, viz., LENPA (Low Energy Neutral Particle Analyzer) with 10–200 keV energy range and HENPA (High Energy Neutral Particle Analyzer) with 0.1–4.0MeV energy range. Simultaneous operation of both analyzers in different energy ranges enables researchers to measure the DT fuel ratio both in the central burning plasma (thermonuclear burn zone) and at the edge as well. When developing the diagnostic complex, it was necessary to account for the impact of several factors: high levels of neutron and gamma radiation, the direct vacuum connection to the ITER vessel, implying high tritium containment, strict requirements on reliability of all units and mechanisms, and the limited space available for accommodation of the diagnostic hardware at the ITER tokamak. The paper describes the design of the diagnostic complex and the engineering solutions that make it possible to conduct measurements under tokamak reactor conditions. The proposed engineering solutions provide a safe—with respect to thermal and mechanical loads—common vacuum channel for hydrogen isotope atoms to pass to the analyzers; ensure efficient shielding of the analyzers from the ITER stray magnetic field (up to 1 kG); provide the remote control of the NPA diagnostic complex, in particular, connection/disconnection of the NPA vacuum beamline from the ITER vessel; meet the ITER radiation safety requirements; and ensure measurements of the fuel isotopic ratio under high levels of neutron and gamma radiation.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1973

Redundancy management of inertial systems.

The paper reviews developments in failure detection and isolation techniques applicable to gimballed and strapdown systems. It examines basic redundancy management goals of improved reliability, performance and logistic costs, and explores mechanizations available for both input and output data handling. The meaning of redundant system reliability in terms of available coverage, system MTBF, and mission time is presented and the practical hardware performance limitations of failure detection and isolation techniques are explored. Simulation results are presented illustrating implementation coverages attainable considering IMU performance models and mission detection threshold requirements. The implications of a complete GN&C redundancy management method on inertial techniques are also explored.

Mckern, R. A.↗

NASA NTRS1975

Impact of coverage on the reliability of a fault tolerant computer

A mathematical reliability model is established for a reconfigurable fault tolerant avionic computer system utilizing state-of-the-art computers. System reliability is studied in light of the coverage probabilities associated with the first and second independent hardware failures. Coverage models are presented as a function of detection, isolation, and recovery probabilities. Upper and lower bonds are established for the coverage probabilities and the method for computing values for the coverage probabilities is investigated. Further, an architectural variation is proposed which is shown to enhance coverage.

Bavuso, S. J.↗

NASA NTRS1994

Toward astrometric tracking with the infrared spatial interferometer

Infrared interferometric demonstrations with the University of California, Berkeley's infrared spatial interferometer (ISI) on Mt. Wilson explore the potential of infrared and optical astrometry for deep space tracking, reference frame development, and DSN science. Astrometric data taken and analyzed over the last five years from the ISI have shown that instrumental and atmospheric effects limit current demonstrations. The benefits of sensitivity upgrades, which were performed in 1991 and 1992, have been demonstrated by comparing point-to-point phase fluctuations for the fall 1989 and fall 1992 observing epochs. This comparison showed that point-to-point phase fluctuations due to tropospheric and quantum noise, for optimal integration times of 0.2 sec, are approaching the 0.1-cycle level needed to reliably connect the interferometric phase. The increase in sensitivity, coupled with that arising from very recent hardware upgrades, will greatly enhance phase-connection capabilities necessary for astrometry in the presence of atmospheric refractivity fluctuations. The current data set suggests that atmospheric fluctuations on Mt. Wilson during the best seeing are dominated by a low-lying component, approximately 25 m high, which may be minimized with in situ calibration in the future. During poor seeing conditions that currently prohibit the interferometric phase connection necessary for astrometry, fluctuations seem to be generated by atmospheric inhomogeneities at much higher altitudes above Mt. Wilson. Data taken over the last year suggest that the ISI will soon be able to achieve 50- to 100-nrad astrometry in a single observing session, employing current ground-based laser distance interferometer calibrations to minimize atmospheric effects.

Treuhaft, R. N.↗

NASA NTRS1998

High Rate Digital Demodulator ASIC

The architecture of High Rate (600 Mega-bits per second) Digital Demodulator (HRDD) ASIC capable of demodulating BPSK and QPSK modulated data is presented in this paper. The advantages of all-digital processing include increased flexibility and reliability with reduced reproduction costs. Conventional serial digital processing would require high processing rates necessitating a hardware implementation in other than CMOS technology such as Gallium Arsenide (GaAs) which has high cost and power requirements. It is more desirable to use CMOS technology with its lower power requirements and higher gate density. However, digital demodulation of high data rates in CMOS requires parallel algorithms to process the sampled data at a rate lower than the data rate. The parallel processing algorithms described here were developed jointly by NASA's Goddard Space Flight Center (GSFC) and the Jet Propulsion Laboratory (JPL). The resulting all-digital receiver has the capability to demodulate BPSK, QPSK, OQPSK, and DQPSK at data rates in excess of 300 Mega-bits per second (Mbps) per channel. This paper will provide an overview of the parallel architecture and features of the HRDR ASIC. In addition, this paper will provide an over-view of the implementation of the hardware architectures used to create flexibility over conventional high rate analog or hybrid receivers. This flexibility includes a wide range of data rates, modulation schemes, and operating environments. In conclusion it will be shown how this high rate digital demodulator can be used with an off-the-shelf A/D and a flexible analog front end, both of which are numerically computer controlled, to produce a very flexible, low cost high rate digital receiver.

Ghuman, Parminder↗

NASA NTRS1999

Test Results for the Automated Rendezvous and Capture System

The Automated Rendezvous and Capture (AR&C) system was designed and tested at NASA's Marshall Space Flight Center (MSFC) to demonstrate technologies and mission strategies for automated rendezvous and docking of spacecraft in Earth orbit, The system incorporates some of the latest innovations in Global Positioning, System space navigation, laser sensor technologies and automated mission sequencing algorithms. The system's initial design and integration was completed in 1998 and has undergone testing at MSFC. This paper describes the major components of the AR&C system and presents results from the official system tests performed in MSFC's Flight Robotics Laboratory with digital simulations and hardware in the loop tests. The results show that the AR&C system can safely and reliably perform automated rendezvous and docking missions in the absence of system failures with 100 percent success. When system failures are included, the system uses its automated collision avoidance maneuver logic to recover in a safe manner. The primary objective of the AR&C project is to prove that by designing a safe and robust automated system, mission operations cost can be reduced by decreasing the personnel required for mission design, preflight planning and training required for crewed rendezvous and docking missions.

Cruzen, Craig↗

NASA NTRS2015

Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718

The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human-rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30-sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post-processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one-way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.

Prater, T.↗

NASA NTRS2016

Selection of a Brine Processor Technology for NASA Manned Missions

The current ISS Water Recovery System (WRS) reclaims water from crew urine, humidity condensate, and Sabatier product water. Urine is initially processed by the Urine Processor Assembly (UPA) which recovers 75% of the urine as distillate. The remainder of the water is present in the waste brine which is currently disposed of as trash on ISS. For future missions this additional water must be reclaimed due to the significant resupply penalty for missions beyond Low Earth Orbit (LEO). NASA has pursued various technology development programs for a brine processor in the past several years. This effort has culminated in a technology down-select to identify the optimum technology for future manned missions. The technology selection is based on various criteria, including mass, power, reliability, maintainability, and safety. Beginning in 2016 the selected technology will be transitioned to a flight hardware program for demonstration on ISS. This paper summarizes the technology selection process, the competing technologies, and the rationale for the technology selected for future manned missions.

Carter, Donald L.↗

DOE OSTI2015

SRAM-Based Digital Arbiter PUF

The increased use of Field Programmable Gate Arrays (FPGAs) in critical systems brings new challenges in securing the diversely programmable fabric from cyber-attacks. FPGAs are an inexpensive, efficient, and flexible alternative to Application Specific Integrated Circuits (ASICs), which are becoming increasingly expensive and impractical for low volume manufacturing as technology nodes continue to shrink. Unfortunately, FPGAs are not designed for high security applications, and their high-flexibility lends itself to low security and vulnerability to malicious attacks. Similar to securing an ASIC’s functionality, FPGA programmers can exploit the inherent randomness introduced into hardware structures during fabrication for security applications. Physically Unclonable Functions (PUFs) are one such solution that uses the die specific variability in hardware fabrication for both secret key generation and verification. PUFs strive to be random, unique, and reliable. Throughout recent years many PUF structures have been presented to try and maximize these three design constraints, reliability being the most difficult of the three to achieve. This thesis presents a new PUF structure that combines two elementary PUF concepts (a bi-stable SRAM PUF and a delay-based arbiter PUF) to create a PUF with increased reliability, while maintaining both random and unique qualities. Properties of the new PUF will be discussed as well as the various design modifications that can be made to tweak the desired performance and overhead.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2011

Keeping checkpoint/restart viable for exascale systems.

Next-generation exascale systems, those capable of performing a quintillion (10{sup 18}) operations per second, are expected to be delivered in the next 8-10 years. These systems, which will be 1,000 times faster than current systems, will be of unprecedented scale. As these systems continue to grow in size, faults will become increasingly common, even over the course of small calculations. Therefore, issues such as fault tolerance and reliability will limit application scalability. Current techniques to ensure progress across faults like checkpoint/restart, the dominant fault tolerance mechanism for the last 25 years, are increasingly problematic at the scales of future systems due to their excessive overheads. In this work, we evaluate a number of techniques to decrease the overhead of checkpoint/restart and keep this method viable for future exascale systems. More specifically, this work evaluates state-machine replication to dramatically increase the checkpoint interval (the time between successive checkpoint) and hash-based, probabilistic incremental checkpointing using graphics processing units to decrease the checkpoint commit time (the time to save one checkpoint). Using a combination of empirical analysis, modeling, and simulation, we study the costs and benefits of these approaches on a wide range of parameters. These results, which cover of number of high-performance computing capability workloads, different failure distributions, hardware mean time to failures, and I/O bandwidths, show the potential benefits of these techniques for meeting the reliability demands of future exascale platforms.

99 GENERAL AND MISCELLANEOUS↗

NASA NTRS1993

Interdisciplinary technology

The 'computational test-cell' will enable the incorporation of new methodologies, such as concurrent engineering and probabilistic methods, into the propulsion design process. This will provide the capability to conduct credible, interdisciplinary analyses of new propulsion concepts and designs. Probabilistic methods can be used as the basis for reliability-based design. Recently methods have been devised that provide the capability of simulating the performance of propulsion systems at several levels of resolution. These methods make it possible to quantify uncertainty and to establish confidence bounds for the calculated values. The introduction of reliability-based design methodology along with probabilistic analyses will provide a tool to reduce the design space for new systems and to reduce our dependence on hardware testing for proof-of-concept and system integration demonstrations. The resulting simulations will reduce the need for testing and identify potential operational problems early in the design process. This capability will make it possible to compute the expected performance, stability, reliability, and life of propulsion components, subsystems, and systems at design and off-design conditions, to bring life cycle cost trade-offs early into the design process and to determine optimum designs to satisfy specified mission requirements.

Nichols, Lester D.↗

NASA NTRS1984

The implementation and use of Ada on distributed systems with high reliability requirements

The use and implementation of Ada (a trade mark of the US Dept. of Defense) in distributed environments in which the hardware are assumed to be unreliable were investigated. The possibility that a distributed system is programmed entirely in Ada so that the individual tasks of the system are unconcerned with which processors they are executing on and failures occurring in the underlying hardware were examined.

Knight, J. C.↗

DOE OSTI2024

Demonstrating autonomous controls on hardware test beds is a necessity for successful missions to Mars and beyond

NASA and the Department of Defense are planning for a mission to Mars in the 2030s–2040s using nuclear thermal propulsion (NTP). NTP uses a nuclear reactor to heat flowing hydrogen and create thrust. A serious concern for crewed and uncrewed missions to Mars is the loss of reactor control. The reactor startup and initial rocket impulse are initiated in cislunar or near-earth orbital regions; therefore, radio communications between ground control and the NTP engine should occur in real time. However, radio communications can take more than 20 min, depending on planet positions, to reach Mars orbiters from ground control. To address this delay, local autonomous controls are implemented onboard the NTP engine to ensure acceptable operation. However, autonomous controls have not been demonstrated or implemented in research or power reactor contexts because of safety and reliability concerns. To enable autonomous controls development, demonstration, and validation, Oak Ridge National Laboratory has created a nonnuclear hardware-in-the-loop test bed. Sensors throughout the test bed relay system status and hardware response to the user control algorithm, including measurements of temperature, flow, pressure of a loop, control drum position, and drum speed. This paper discusses the development of this facility and user accessibility.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2017

Summary: High Temperature Downhole Motor

Directional drilling can be used to enable multi-lateral completions from a single well pad to improve well productivity and decrease environmental impact. Downhole rotation is typically developed with a motor in the Bottom Hole Assembly (BHA) that develops drilling power (speed and torque) necessary to drive rock reduction mechanisms (i.e., the bit) apart from the rotation developed by the surface rig. Historically, wellbore deviation has been introduced by a “bent-sub,” located in the BHA, that introduces a small angular deviation, typically less than 3 degrees, to allow the bit to drill off-axis with orientation of the BHA controlled at the surface. The development of a high temperature downhole motor would allow reliable use of bent subs for geothermal directional drilling. Sandia National Laboratories is pursuing the development of a high temperature motor that will operate on either drilling fluid (water-based mud) or compressed air to enable drilling high temperature, high strength, fractured rock. The project consists of designing a power section based upon geothermal drilling requirements; modeling and analysis of potential solutions; and design, development and testing of prototype hardware to validate the concept. Drilling costs contribute substantially to geothermal electricity production costs. The present development will result in more reliable access to deep, hot geothermal resources and allow preferential wellbore trajectories to be achieved. This will enable development of geothermal wells with multi-lateral completions resulting in improved geothermal resource recovery, decreased environmental impact and enhanced well construction economics.

42 ENGINEERING↗

NASA NTRS2015

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS; and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. For NASA's SLS ABEDRR procurement, Dynetics and AR formed a team to offer a series of full-scale risk mitigation hardware demonstrations for an affordable booster approach that meets the evolved capabilities of the SLS. To establish a basis for the risk reduction activities, the Dynetics Team developed a booster design that takes advantage of the flight-proven Apollo-Saturn F-1. Using NASA's vehicle assumptions for the SLS Block 2, a two-engine, F-1-based booster design delivers 150 mT (331 klbm) payload to LEO, 20 mT (44 klbm) above NASA's requirements. This enables a low-cost, robust approach to structural design. During the ABEDRR effort, the Dynetics Team has modified proven Apollo-Saturn components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically produced Atlas V engine that could also potentially satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete critical design review this fall and begin testing in 2017. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements. This paper will discuss the ABEDRR engine task and structures task achievements to date and the remaining effort through the end of the contract.

Crocker, Andrew M.↗

NASA NTRS1987

Hardware fault insertion and instrumentation system: Mechanization and validation

Automated test capability for extensive low-level hardware fault insertion testing is developed. The test capability is used to calibrate fault detection coverage and associated latency times as relevant to projecting overall system reliability. Described are modifications made to the NASA Ames Reconfigurable Flight Control System (RDFCS) Facility to fully automate the total test loop involving the Draper Laboratories' Fault Injector Unit. The automated capability provided included the application of sequences of simulated low-level hardware faults, the precise measurement of fault latency times, the identification of fault symptoms, and bulk storage of test case results. A PDP-11/60 served as a test coordinator, and a PDP-11/04 as an instrumentation device. The fault injector was controlled by applications test software in the PDP-11/60, rather than by manual commands from a terminal keyboard. The time base was especially developed for this application to use a variety of signal sources in the system simulator.

Benson, J. W.↗

DOE OSTI2019

Blackcomb2: Hardware-Software Co-design for Nonvolatile Memory in Exascale Systems

The impending shift from DRAM and Flash to fast nonvolatile memory (NVM) provides a game-changing opportunity to rethink traditional system architectures; to address their energy inefficiencies; to leverage the new devices for greater performance; and to exploit the new capability of nonvolatility to enhance system resilience, even in the face of larger system scale and degraded reliability of components. Building on the accomplishments of the Blackcomb Project, funded in 2010, we propose to identify, evaluate, and optimize the most promising NVM hardware and software technologies, which are essential to provide the necessary memory capacity, performance, resilience, and energy efficiency in exascale systems. Capacity and energy are the key drivers. Today's pressing application requirements mandate exascale computing; the datasets and concurrency of these applications demand memory capacity that cannot be met by traditional memory technologies. Although charge-based DRAM will endure, experts foresee only modest DRAM capacity gains. And, as moving data between levels of the hierarchy, and storing and accessing data on disk consumes significant energy, a more energy efficient solution is required. We, therefore, posit that exascale systems will need high density, energy-efficient storage technologies, such as nonvolatile memory for access, transformation, and management of exascale data. To address these issues, in this renewal request, we propose continue the work of our vertically- integrated, focussed team, where our co-design is informed by proxies and interactions with DOE co-design centers. In software, we start by assuming that nonvolatility requires new abstractions and new infrastructure, allowing persistent objects, and delivering performance gains for _le systems and robustness through fast checkpointing. In architecture, we evaluate the tradeoffs of performance and energy by employing a scalable and accurate simulation system to analyze realistic proxy applications. Through this co-design process, we rethink the whole memory architecture, from the cell to the array to the device, with ECC, wearout management, and interfaces. Finally, we provide open-source software models of these NVM-based memory systems.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS2018

Improving Logistics and Waste Management for Deep Space Human Exploration

NASA's Advanced Exploration Systems Logistics Reduction Project is developing technologies that reduce mission mass and volume for exploration. Recently there has been increasing interest in determining the quantity of consumable logistics and system spares necessary to ensure a certain level of reliability. This is influenced by a technology's criticality and degree of impact to the overall mission. Technologies that directly reduce mass (e.g. longer wear crew clothing) are relatively straightforward for calculating the savings and understanding the mission impacts. Waste management technologies that process waste can reduce mass, but spares and contingency modes are more interwoven with other vehicle systems, so assessment is more complex. This paper considers mission benefits while also considering impacts from hardware failures for technologies including: crew clothing, reusable cargo bags for habitat outfitting, automated RFID cargo tracking, trash processing/storage/repurposing, and high reliability toilets.

Broyan, James Lee, Jr.↗