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NASA NTRS1986

Software development to support sensor control of robot arc welding

The development of software for a Digital Equipment Corporation MINC-23 Laboratory Computer to provide functions of a workcell host computer for Space Shuttle Main Engine (SSME) robotic welding is documented. Routines were written to transfer robot programs between the MINC and an Advanced Robotic Cyro 750 welding robot. Other routines provide advanced program editing features while additional software allows communicatin with a remote computer aided design system. Access to special robot functions were provided to allow advanced control of weld seam tracking and process control for future development programs.

Silas, F. R., Jr.↗

NASA NTRS1988

The Atlas-Centaur 67 incident

The conditions leading to the breakup of the Atlas-Centaur 67 (AC-67) vehicle launched on March 26, 1987 during a typical winter-time storm are analyzed, and a most probable lightning strike scenario was developed based on inspection of the AC-67 debris, the AC-68 vehicle, and appropriate drawings, electrical diagrams, and photographs. It is shown that, during ascent, the vehicle encountered increasingly larger electric fields and flew through clouds that produced precipitation static on the vehicle, eventually triggering a cloud-to-ground lightning, comprised of at least four return strokes. The resulting lightning current coupled a signal into the wiring which goes to the AC-67 digital computer unit (DCU), effecting a single-word memory alteration and causing the DCU to issue a hardover engine gimbal command. This led to an excessive angle of attack, large dynamic loads, and the breakup of the AC-67.

Christian, H. J.↗

NASA NTRS2007

Monitoring by Use of Clusters of Sensor-Data Vectors

The inductive monitoring system (IMS) is a system of computer hardware and software for automated monitoring of the performance, operational condition, physical integrity, and other aspects of the health of a complex engineering system (e.g., an industrial process line or a spacecraft). The input to the IMS consists of streams of digitized readings from sensors in the monitored system. The IMS determines the type and amount of any deviation of the monitored system from a nominal or normal ( healthy ) condition on the basis of a comparison between (1) vectors constructed from the incoming sensor data and (2) corresponding vectors in a database of nominal or normal behavior. The term inductive reflects the use of a process reminiscent of traditional mathematical induction to learn about normal operation and build the nominal-condition database. The IMS offers two major advantages over prior computational monitoring systems: The computational burden of the IMS is significantly smaller, and there is no need for abnormal-condition sensor data for training the IMS to recognize abnormal conditions. The figure schematically depicts the relationships among the computational processes effected by the IMS. Training sensor data are gathered during normal operation of the monitored system, detailed computational simulation of operation of the monitored system, or both. The training data are formed into vectors that are used to generate the database. The vectors in the database are clustered into regions that represent normal or nominal operation. Once the database has been generated, the IMS compares the vectors of incoming sensor data with vectors representative of the clusters. The monitored system is deemed to be operating normally or abnormally, depending on whether the vector of incoming sensor data is or is not, respectively, sufficiently close to one of the clusters. For this purpose, a distance between two vectors is calculated by a suitable metric (e.g., Euclidean distance) and "sufficiently close" signifies lying at a distance less than a specified threshold value. It must be emphasized that although the IMS is intended to detect off-nominal or abnormal performance or health, it is not necessarily capable of performing a thorough or detailed diagnosis. Limited diagnostic information may be available under some circumstances. For example, the distance of a vector of incoming sensor data from the nearest cluster could serve as an indication of the severity of a malfunction. The identity of the nearest cluster may be a clue as to the identity of the malfunctioning component or subsystem. It is possible to decrease the IMS computation time by use of a combination of cluster-indexing and -retrieval methods. For example, in one method, the distances between each cluster and two or more reference vectors can be used for the purpose of indexing and retrieval. The clusters are sorted into a list according to these distance values, typically in ascending order of distance. When a set of input data arrives and is to be tested, the data are first arranged as an ordered set (that is, a vector). The distances from the input vector to the reference points are computed. The search of clusters from the list can then be limited to those clusters lying within a certain distance range from the input vector; the computation time is reduced by not searching the clusters at a greater distance.

Iverson, David L.↗

NASA NTRS1999

Experiments on Evolving Software Models of Analog Circuits

Analog circuits are of great importance in electronic system design since the world is fundamentally analog in nature. While the amount of digital design activity far outpaces that of analog design, most digital systems require analog modules for interfacing with the external world. It was recently estimated that approximately 60% of digital application- specific integrated circuit designs incorporated analog circuits. With challenging analog circuit design problems and few analog design engineers, there are economic reasons for automating the analog design process, especially time-to-market considerations. Techniques for analog circuit design automation began appearing about two decades ago. These methods incorporated heuristics [6], knowledge bases [1], simulated annealing [5], and other algorithms. Efforts using techniques from evolutionary computation began appearing over the last few years. These include the use of genetic algorithms to select electronic component values (for example, the resistance value of a resistor), to select circuit topologies, and to design amplifiers using a limited set of canned topologies [4]. A genetic programming-based analog circuit design system has been demonstrated in which the circuit sizes, component values, and the circuit topologies are determined automatically [3]. The genetic-algorithm systems typically represent circuit structures as vectors of parameters encoded in binary strings, while the genetic programming system manipulates tree data structures.

Lohn, Jason D.↗

NASA NTRS2012

Simulation of Image Performance Characteristics of the Landsat Data Continuity Mission (LDCM) Thermal Infrared Sensor (TIRS)

The next Landsat satellite, which is scheduled for launch in early 2013, will carry two instruments: the Operational Land Imager (OLI) and the Thermal Infrared Sensor (TIRS). Significant design changes over previous Landsat instruments have been made to these sensors to potentially enhance the quality of Landsat image data. TIRS, which is the focus of this study, is a dual-band instrument that uses a push-broom style architecture to collect data. To help understand the impact of design trades during instrument build, an effort was initiated to model TIRS imagery. The Digital Imaging and Remote Sensing Image Generation (DIRSIG) tool was used to produce synthetic "on-orbit" TIRS data with detailed radiometric, geometric, and digital image characteristics. This work presents several studies that used DIRSIG simulated TIRS data to test the impact of engineering performance data on image quality in an effort to determine if the image data meet specifications or, in the event that they do not, to determine if the resulting image data are still acceptable.

Landsat↗

NASA NTRS2016

Hybrid Reality Lab Capabilities - Video 2

Our Hybrid Reality and Advanced Operations Lab is developing incredibly realistic and immersive systems that could be used to provide training, support engineering analysis, and augment data collection for various human performance metrics at NASA. To get a better understanding of what Hybrid Reality is, let's go through the two most commonly known types of immersive realities: Virtual Reality, and Augmented Reality. Virtual Reality creates immersive scenes that are completely made up of digital information. This technology has been used to train astronauts at NASA, used during teleoperation of remote assets (arms, rovers, robots, etc.) and other activities. One challenge with Virtual Reality is that if you are using it for real time-applications (like landing an airplane) then the information used to create the virtual scenes can be old (i.e. visualized long after physical objects moved in the scene) and not accurate enough to land the airplane safely. This is where Augmented Reality comes in. Augmented Reality takes real-time environment information (from a camera, or see through window, and places digitally created information into the scene so that it matches with the video/glass information). Augmented Reality enhances real environment information collected with a live sensor or viewport (e.g. camera, window, etc.) with the information-rich visualization provided by Virtual Reality. Hybrid Reality takes Augmented Reality even further, by creating a higher level of immersion where interactivity can take place. Hybrid Reality takes Virtual Reality objects and a trackable, physical representation of those objects, places them in the same coordinate system, and allows people to interact with both objects' representations (virtual and physical) simultaneously. After a short period of adjustment, the individuals begin to interact with all the objects in the scene as if they were real-life objects. The ability to physically touch and interact with digitally created objects that have the same shape, size, location to their physical object counterpart in virtual reality environment can be a game changer when it comes to training, planning, engineering analysis, science, entertainment, etc. Our Project is developing such capabilities for various types of environments. The video outlined with this abstract is a representation of an ISS Hybrid Reality experience. In the video you can see various Hybrid Reality elements that provide immersion beyond just standard Virtual Reality or Augmented Reality.

Delgado, Francisco J.↗

NASA NTRS2004

Multi-level Simulation of a Real Time Vibration Monitoring System Component

This paper describes the development of a custom built Digital Signal Processing (DSP) printed circuit board designed to implement the Advanced Real Time Vibration Monitoring Subsystem proposed by MSFC Transportation Directorate in 2000 for the Space Shuttle Main Engine Advanced Health Management System (AHMS). This Real Time Vibration Monitoring System (RTVMS) is being developed for ground use as part of the AHMS Health Management Computer-Integrated Rack Assembly (HMC-IRA). The HMC-IRA RTVMS design contains five DSPs which are highly interconnected through individual communication ports, shared memory, and a unique communication router that allows all the DSPs to receive digitized data from two multi-channel analog boards simultaneously. This paper will briefly cover the overall board design but will focus primarily on the state-of-the-art simulation environment within which this board was developed. This 16-layer board with over 1800 components and an additional mezzanine card has been an extremely challenging design. Utilization of a Mentor Graphics simulation environment provided the unique board and system level simulation capability to ascertain any timing or functional concerns before production. By combining VHDL, Synopsys Software and Hardware Models, and the Mentor Design Capture Environment, multiple simulations were developed to verify the RTVMS design. This multi-level simulation allowed the designers to achieve complete operability without error the first time the RTVMS printed circuit board was powered. The HMCIRA design has completed all engineering unit testing and the deliverable unit is currently under development.

Roberston, Bryan↗

NASA NTRS2002

Presentation to Ohio State University Dept. of Electrical Engineering ElectroScience Laboratory

Presentation made during visit to The Ohio State University, ElectroScience Laboratory, on November 14, 2002. An overview of NASA and selected technology products from the Digital Communications Technology Branch (5650) for fiscal year 2003 are highlighted. The purpose of the meeting was to exchange technical information on current aeronautics and space communications research and technology being conducted at NASA Glenn Research Center and to promote faculty/student collaborations of mutual interest.

Fujikawa, Gene↗

NASA NTRS2018

Digital Image Correlation Data Processing and Analysis Techniques to Enhance Test Data Assessment and Improve Structural Simulations

The NASA Shell Buckling Knockdown Factor Project (SBKF) was established in 2007 by the NASA Engineering and Safety Center (NESC) with the primary goal to develop new analysis-based buckling design factors (a.k.a. knockdown factors) and high-fidelity buckling simulations for selected launch-vehicle-like cylindrical shell structures. A series of tests are being conducted on large-scale metallic and composite cylindrical shells in order to provide validation data for these new factors and simulations. However, the validation of these new factors and simulations is quite demanding and requires test data that is commensurate with their fidelity. Traditional instrumentation, such as linear variable displacement transducers (LVDTs) and electrical-resistance strain gages serve a critical role in providing accurate displacement and strain measurements in these tests, but only allow for data to be recorded at a select number of point locations and are not sufficient to provide all the necessary validation data. Advanced measurement technologies can be used effectively to complement traditional instrumentation and gather additional data required to validate these structural simulations. In particular, three-dimensional digital image correlation (DIC) was implemented during SBKF cylinder testing to characterize the full-field displacement and strain behavior. Commercially available VIC-3DTM software and user-written data processing scripts were used to generate valuable data and insight into the complex buckling response of the cylinders that otherwise would be impossible to gather using traditional instrumentation. In addition, the measured data from DIC was used to verify measured test data obtained from other instrumentation, enhance test and analysis correlation, and help identify the root cause of anomalous test results that may have gone unexplained if only traditional instrumentation was used. Selected test results that demonstrate the use of DIC on the SBKF cylinders are presented and a portion of the data processing methods are described.

Gardner, Nathaniel W.↗

NASA NTRS1996

DGPS with NASA's ACTS

The U.S. Army Topographic Engineering Center, concerned about frequency license problems inherent with operating data-ready radios to support differential GPS (DGPS), learned of an experiment program the National Aeronautics and Space Administration (NASA) was sponsoring with its prototype digital satellite - the Advanced Communications Technology Satellite (ACTS). ACTS was designed to evaluate many new, untested technologies for eventual transfer to U.S. telecommunications and related industries. The new technologies promised greater data transmission rates and significantly reduced transmission latency. recognizing these benefits, the Topographic Engineering Center designed a DGPS experiment using an ACTS datalink with baselines of 200 kilometers and longer to learn what positional accuracy was possible with leading-edge satellite telecommunications technology.

Dendy, Roger↗

NASA NTRS2007

"Smart" Sensor Module

An assembly that contains a sensor, sensor-signal-conditioning circuitry, a sensor-readout analog-to-digital converter (ADC), data-storage circuitry, and a microprocessor that runs special-purpose software and communicates with one or more external computer(s) has been developed as a prototype of "smart" sensor modules for monitoring the integrity and functionality (the "health") of engineering systems. Although these modules are now being designed specifically for use on rocket-engine test stands, it is anticipated that they could also readily be designed to be incorporated into health-monitoring subsystems of such diverse engineering systems as spacecraft, aircraft, land vehicles, bridges, buildings, power plants, oilrigs, and defense installations. The figure is a simplified block diagram of the "smart" sensor module. The analog sensor readout signal is processed by the ADC, the digital output of which is fed to the microprocessor. By means of a standard RS-232 cable, the microprocessor is connected to a local personal computer (PC), from which software is downloaded into a randomaccess memory in the microprocessor. The local PC is also used to debug the software. Once the software is running, the local PC is disconnected and the module is controlled by, and all output data from the module are collected by, a remote PC via an Ethernet bus. Several smart sensor modules like this one could be connected to the same Ethernet bus and controlled by the single remote PC. The software running in the microprocessor includes driver programs for operation of the sensor, programs that implement self-assessment algorithms, programs that implement protocols for communication with the external computer( s), and programs that implement evolutionary methodologies to enable the module to improve its performance over time. The design of the module and of the health-monitoring system of which it is a part reflects the understanding that the main purpose of a health-monitoring system is to detect damage and, therefore, the health-monitoring system must be able to function effectively in the presence of damage and should be capable of distinguishing between damage to itself and damage to the system being monitored. A major benefit afforded by the self-assessment algorithms is that in the output of the module, the sensor data indicative of the health of the engineering system being monitored are coupled with a confidence factor that quantifies the degree of reliability of the data. Hence, the output includes information on the health of the sensor module itself in addition to information on the health of the engineering system being monitored.

Mahajan, Ajay↗

NASA NTRS1980

Aeropropulsion in year 2000

The paper demonstrates that many advances can be anticipated in propulsion systems for aircraft in the next 20 years. A survey is presented of probable future engine types, including convertible engines for helicopters, turboprops for fuel efficient airliners, and variable cycle engines for supersonic transports. Also examined is the use of rotary engines in general aviation aircraft. Finally, a review is given of related technology improvements in propellers, materials, noise suppression, and digital electronic controls.

Weber, R. J.↗

NASA NTRS1985

Flight test experience and controlled impact of a large, four-engine, remotely piloted airplane

A controlled impact demonstration (CID) program using a large, four engine, remotely piloted transport airplane was conducted. Closed loop primary flight control was performed from a ground based cockpit and digital computer in conjunction with an up/down telemetry link. Uplink commands were received aboard the airplane and transferred through uplink interface systems to a highly modified Bendix PB-20D autopilot. Both proportional and discrete commands were generated by the ground pilot. Prior to flight tests, extensive simulation was conducted during the development of ground based digital control laws. The control laws included primary control, secondary control, and racetrack and final approach guidance. Extensive ground checks were performed on all remotely piloted systems. However, manned flight tests were the primary method of verification and validation of control law concepts developed from simulation. The design, development, and flight testing of control laws and the systems required to accomplish the remotely piloted mission are discussed.

Kempel, R. W.↗

NASA NTRS1985

Flight test experience and controlled impact of a large, four-engine remotely piloted airplane

A controlled impact demonstration (CID) program using a large, four engine, remotely piloted transport airplane was conducted. Closed loop primary flight control was performed from a ground based cockpit and digital computer in conjunction with an up/down telemetry link. Uplink commands were received aboard the airplane and transferred through uplink interface systems to a highly modified Bendix PB-20D autopilot. Both proportional and discrete commands were generated by the ground pilot. Prior to flight tests, extensive simulation was conducted during the development of ground based digital control laws. The control laws included primary control, secondary control, and racetrack and final approach guidance. Extensive ground checks were performed on all remotely piloted systems. However, manned flight tests were the primary method of verification and validation of control law concepts developed from simulation. The design development, and flight testing of control laws and the systems required to accomplish the remotely piloted mission are discussed.

Kempel, R. W.↗

NASA NTRS1990

Digital filtering of plume emission spectra

Fourier transformation and digital filtering techniques were used to separate the superpositioned spectral phenomena observed in the exhaust plumes of liquid propellant rocket engines. Space shuttle main engine (SSME) spectral data were used to show that extraction of spectral lines in the spatial frequency domain does not introduce error, and extraction of the background continuum introduces only minimal error. Error introduced during band extraction could not be quantified due to poor spectrometer resolution. Based on the atomic and molecular species found in the SSME plume, it was determined that spectrometer resolution must be 0.03 nm for SSME plume spectral monitoring.

Madzsar, George C.↗

NASA NTRS1990

Digital filtering of plume emission spectra

Madzsar, George C.↗

NASA NTRS2002

Application of DPIV to Enhanced Mixing Heated Nozzle Flows

Digital Particle Imaging Velocimetry (DPIV) is a planar velocity measurement technique that continues to be applied to new and challenging engineering research facilities while significantly reducing facility test time. DPIV was used in the GRC Nozzle Acoustic Test Rig (NATR) to characterize the high temperature (560 C), high speed (is greater than 500 m/s) flow field properties of mixing enhanced jet engine nozzles. The instantaneous velocity maps obtained using DPIV were used to determine mean velocity, rms velocity and two-point correlation statistics to verify the true turbulence characteristics of the flow. These measurements will ultimately be used to properly validate aeroacoustic model predictions by verifying CFD input to these models. These turbulence measurements have previously not been possible in hot supersonic jets. Mapping the nozzle velocity field using point based techniques requires over 60 hours of test time, compared to less than 45 minutes using DPIV, yielding a significant reduction in testing time. A dual camera DPIV configuration was used to maximize the field of view and further minimize the testing time required to map the nozzle flow. The DPIV system field of view covered 127 by 267 mm. Data were acquired at 19 axial stations providing coverage of the flow from the nozzle exit to 2.37 in downstream. At each measurement station, 400 image frame pairs were acquired from each camera. The DPIV measurements of the mixing enhanced nozzle designs illustrate the changes in the flow field resulting in the reduced noise signature.

Wernet, Mark P.↗

NASA NTRS2015

Application of Optical Measurement Techniques During Fabrication and Testing of Liquid Rocket Nozzles

This paper presents a series of optical measurement techniques that were developed for use during large-scale fabrication and testing of nozzle components. A thorough understanding of hardware throughout the fabrication cycle and hotfire testing is critical to meet component design intent. Regeneratively cooled nozzles and associated tooling require tight control of tolerances during the fabrication process to ensure optimal performance. Additionally, changes in geometry during testing can affect performance of the nozzle and mating components. Structured light scanning and digital image correlation techniques were used to collect data during the fabrication and test of nozzles, in addition to other engine components. This data was used to analyze deformations data during machining, heat treatment, assembly and testing operations. A series of feasibility experiments were conducted for these techniques that led to use on full scale nozzles during the J-2X upper stage engine program in addition to other engine development programs. This paper discusses the methods and results of these measurement techniques throughout the nozzle life cycle and application to other components.

Gradl, Paul R.↗