A Discussion of the Failure of a Quad Diode Module and NESC Efforts to Assure the Flight Spares
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Jay Brusse↗
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Mission Reliability Estimation for Repairable Robot Teams
A mission reliability estimation method has been designed to translate mission requirements into choices of robot modules in order to configure a multi-robot team to have high reliability at minimal cost. In order to build cost-effective robot teams for long-term missions, one must be able to compare alternative design paradigms in a principled way by comparing the reliability of different robot models and robot team configurations. Core modules have been created including: a probabilistic module with reliability-cost characteristics, a method for combining the characteristics of multiple modules to determine an overall reliability-cost characteristic, and a method for the generation of legitimate module combinations based on mission specifications and the selection of the best of the resulting combinations from a cost-reliability standpoint. The developed methodology can be used to predict the probability of a mission being completed, given information about the components used to build the robots, as well as information about the mission tasks. In the research for this innovation, sample robot missions were examined and compared to the performance of robot teams with different numbers of robots and different numbers of spare components. Data that a mission designer would need was factored in, such as whether it would be better to have a spare robot versus an equivalent number of spare parts, or if mission cost can be reduced while maintaining reliability using spares. This analytical model was applied to an example robot mission, examining the cost-reliability tradeoffs among different team configurations. Particularly scrutinized were teams using either redundancy (spare robots) or repairability (spare components). Using conservative estimates of the cost-reliability relationship, results show that it is possible to significantly reduce the cost of a robotic mission by using cheaper, lower-reliability components and providing spares. This suggests that the current design paradigm of building a minimal number of highly robust robots may not be the best way to design robots for extended missions.
Trebi-Ollennu, Ashitey↗
Comments on the MIT Assessment of the Mars One Plan
The MIT assessment of the Mars One mission plan reveals design assumptions that would cause significant difficulties. Growing crops in the crew chamber produces excessive oxygen levels. The assumed in-situ resource utilization (ISRU) equipment has too low a Technology Readiness Level (TRL). The required spare parts cause a large and increasing launch mass logistics burden. The assumed International Space Station (ISS) Environmental Control and Life Support (ECLS) technologies were developed for microgravity and therefore are not suitable for Mars gravity. Growing food requires more mass than sending food from Earth. The large number of spares is due to the relatively low reliability of ECLS and the low TRL of ISRU. The Mars One habitat design is similar to past concepts but does not incorporate current knowledge. The MIT architecture analysis tool for long-term settlements on the Martian surface includes an ECLS system simulation, an ISRU sizing model, and an analysis of required spares. The MIT tool showed the need for separate crop and crew chambers, the large spare parts logistics, that crops require more mass than Earth food, and that more spares are needed if reliability is lower. That ISRU has low TRL and ISS ECLS was designed for microgravity are well known. Interestingly, the results produced by the architecture analysis tool - separate crop chamber, large spares mass, large crop chamber mass, and low reliability requiring more spares - were also well known. A common approach to ECLS architecture analysis is to build a complex model that is intended to be all-inclusive and is hoped will help solve all design problems. Such models can struggle to replicate obvious and well-known results and are often unable to answer unanticipated new questions. A better approach would be to survey the literature for background knowledge and then directly analyze the important problems.
Mars mission↗
The Threat of Uncertainty: Why Using Traditional Approaches for Evaluating Spacecraft Reliability are Insufficient for Future Human Mars Missions
Through the Evolvable Mars Campaign (EMC) study, the National Aeronautics and Space Administration (NASA) continues to evaluate potential approaches for sending humans beyond low Earth orbit (LEO). A key aspect of these missions is the strategy that is employed to maintain and repair the spacecraft systems, ensuring that they continue to function and support the crew. Long duration missions beyond LEO present unique and severe maintainability challenges due to a variety of factors, including: limited to no opportunities for resupply, the distance from Earth, mass and volume constraints of spacecraft, high sensitivity of transportation element designs to variation in mass, the lack of abort opportunities to Earth, limited hardware heritage information, and the operation of human-rated systems in a radiation environment with little to no experience. The current approach to maintainability, as implemented on ISS, which includes a large number of spares pre-positioned on ISS, a larger supply sitting on Earth waiting to be flown to ISS, and an on demand delivery of logistics from Earth, is not feasible for future deep space human missions. For missions beyond LEO, significant modifications to the maintainability approach will be required.Through the EMC evaluations, several key findings related to the reliability and safety of the Mars spacecraft have been made. The nature of random and induced failures presents significant issues for deep space missions. Because spare parts cannot be flown as needed for Mars missions, all required spares must be flown with the mission or pre-positioned. These spares must cover all anticipated failure modes and provide a level of overall reliability and safety that is satisfactory for human missions. This will require a large amount of mass and volume be dedicated to storage and transport of spares for the mission. Further, there is, and will continue to be, a significant amount of uncertainty regarding failure rates for spacecraft components. This uncertainty makes it much more difficult to anticipate failures and will potentially require an even larger amount of spares to provide an acceptable level of safety. Ultimately, the approach to maintenance and repair applied to ISS, focusing on the supply of spare parts, may not be tenable for deep space missions. Other approaches, such as commonality of components, simplification of systems, and in-situ manufacturing will be required.
Stromgren, Chel↗
The optimum cost-effective test time for redundant systems with specified reliability and confidence
This paper investigates the optimum test time to determine the number of redundant units needed to achieve high reliability with high confidence. Newly designed systems often have high initial failure rates which can be reduced by testing to find failure modes and remove them by redesign. To accurately estimate the required number of redundant units, the test time must be extended to accurately determine the failure rate. If the measured failure rate is used, there is a 50% chance that the actual hardware failure rate is higher. Using the measured failure rate gives only a 50% confidence that the failure rate and number of spares are not too low. After the test, given the measured failure rate and the desired reliability, the number of spares can be determined and the confidence in the reliability computed. Instead of accepting the reliability results of a fixed duration test, it is possible to set the requirements for both the redundant reliability and the confidence level and then compute the test time needed to minimize the total cost required to achieve these requirements. The confidence that the redundant reliability is not too low is increased by using a higher than measured failure rate to increase the number of spares. The higher number of spares increases cost. Longer test time reduces the variance in the failure rate and the increase in the number of spares, so that test cost increases and spares cost decreases. The total cost is the sum of the cost of the test time and the spares. The optimum test time produces the minimum total cost for the system failure rate, mission length, and required reliability and confidence level. Longer testing is justified by reduced cost. Some examples are given.
Harry W Jones↗
A Probabilistic Tool that Aids Logistics Engineers in the Establishment of High Confidence Repair Need-Dates at the NASA Shuttle Logistics Depot
The NASA Shuttle Logistics Depot (NSLD) is tasked with the responsibility for repair and manufacture of Line Replaceable Unit (LRU) hardware and components to support the Space Shuttle Orbiter. Due to shrinking budgets, cost effective repair of LRU's becomes a primary objective. To achieve this objective, is imperative that resources be assigned to those LRU's which have the greatest expectation of being needed as a spare. Forecasting the times at which spares are needed requires consideration of many significant factors including: failure rate, flight rate, spares availability, and desired level of support, among others. This paper summarizes the results of the research and development work that has been accomplished in producing an automated tool that assists in the assignment of effective repair start-times for LRU's at the NSLD. This system, called the Repair Start-time Assessment System (RSAS), uses probabilistic modeling technology to calculate a need date for a repair that considers the current repair pipeline status, as well as, serviceable spares and projections of future demands. The output from the system is a date for beginning the repair that has significantly greater confidence (in the sense that a desired probability of support is ensured) than times produced using other techniques. Since an important output of RSAS is the longest repair turn-around time that will ensure a desired probability of support, RSAS has the potential for being applied to operations at any repair depot where spares are on-hand and repair start-times are of interest. In addition, RSAS incorporates tenants of Just-in-Time (JIT) techniques in that the latest repair start-time (i.e., the latest time at which repair resources must be committed) may be calculated for every failed unit This could reduce the spares inventory for certain items, without significantly increasing the risk of unsatisfied demand.
Bullington, J. V.↗
Challenges of Sustaining the International Space Station Through 2020 and Beyond: Reassessing Confidence Targets for System Availability
The International Space Station (ISS) was originally designed to operate until 2015 with a plan for deorbiting the ISS in 2016. Currently, the international partnership has agreed to extend the operations until 2020 and discussions are underway to extend the life even further to 2028. Each partner is responsible for the sustaining engineering, sparing, and maintenance of their own segments. National Aeronautics and Space Administration's (NASA's) challenge is to purchase the needed number of spares to maintain the functional availability of the ISS systems necessary for the United States On-Orbit Segment s contribution. This presentation introduces an analytical approach to assessing uncertainty in ISS hardware necessary to extend the life of the vehicle. Some key areas for consideration are: establishing what confidence targets are required to ensure science can be continuously carried out on the ISS, defining what confidence targets are reasonable to ensure vehicle survivability, considering what is required to determine if the confidence targets are too high, and whether sufficient number of spares are purchased. The results of the analysis will provide a methodological basis for reassessing vehicle subsystem confidence targets. This analysis compares the probability of existing spares exceeding the total expected unit demand of the Orbital Replacement Unit (ORU) in functional hierarchies approximating the vehicle subsystems. In cases where the functional hierarchies' availability does not meet subsystem confidence targets, the analysis will further identify which ORUs may require additional spares to extend the life of the ISS. The resulting probability is dependent upon hardware reliability estimates. However, the ISS hardware fleet carries considerable epistemic uncertainty which must be factored into the development and execution of sparing risk postures. In addition, it is also recognized that uncertainty in the assessment is due to disconnects between modeled functions and actual subsystem operations. Perhaps most importantly, it is acknowledged that conservative confidence targets per subsystem are currently accepted. This presentation will also discuss how subsystem confidence targets may be relaxed based on calculating the level of uncertainty for each corresponding ORU-function. The presentation will conclude with the various strengths and limitations for implementing the analytical approach in sustaining the ISS through end of life; 2020 and beyond.
Lutomski, Michael G.↗
Challenges of Sustaining the International Space Station through 2020 and Beyond: Including Epistemic Uncertainty in Reassessing Confidence Targets
This paper introduces an analytical approach, Probability and Confidence Trade-space (PACT), which can be used to assess uncertainty in International Space Station (ISS) hardware sparing necessary to extend the life of the vehicle. There are several key areas under consideration in this research. We investigate what sparing confidence targets may be reasonable to ensure vehicle survivability and for completion of science on the ISS. The results of the analysis will provide a methodological basis for reassessing vehicle subsystem confidence targets. An ongoing annual analysis currently compares the probability of existing spares exceeding the total expected unit demand of the Orbital Replacement Unit (ORU) in functional hierarchies approximating the vehicle subsystems. In cases where the functional hierarchies availability does not meet subsystem confidence targets, the current sparing analysis further identifies which ORUs may require additional spares to extend the life of the ISS. The resulting probability is dependent upon hardware reliability estimates. However, the ISS hardware fleet carries considerable epistemic uncertainty (uncertainty in the knowledge of the true hardware failure rate), which does not currently factor into the annual sparing analysis. The existing confidence targets may be conservative. This paper will also discuss how confidence targets may be relaxed based on the inclusion of epistemic uncertainty for each ORU. The paper will conclude with strengths and limitations for implementing the analytical approach in sustaining the ISS through end of life, 2020 and beyond.
Anderson, Leif↗
Near-Earth Phase Risk Comparison of Human Mars Campaign Architectures
A risk analysis of the launch, orbital assembly, and Earth-departure phases of human Mars exploration campaign architectures was completed as an extension of a probabilistic risk assessment (PRA) originally carried out under the NASA Constellation Program Ares V Project. The objective of the updated analysis was to study the sensitivity of loss-of-campaign risk to such architectural factors as composition of the propellant delivery portion of the launch vehicle fleet (Ares V heavy-lift launch vehicle vs. smaller/cheaper commercial launchers) and the degree of launcher or Mars-bound spacecraft element sparing. Both a static PRA analysis and a dynamic, event-based Monte Carlo simulation were developed and used to evaluate the probability of loss of campaign under different sparing options. Results showed that with no sparing, loss-of-campaign risk is strongly driven by launcher count and on-orbit loiter duration, favoring an all-Ares V launch approach. Further, the reliability of the all-Ares V architecture showed significant improvement with the addition of a single spare launcher/payload. Among architectures utilizing a mix of Ares V and commercial launchers, those that minimized the on-orbit loiter duration of Mars-bound elements were found to exceed the reliability of no spare all-Ares V campaign if unlimited commercial vehicle sparing was assumed
Manning, Ted A.↗
We Can't Count on Repairing All Failures Going to Mars
Reliability analysis often assumes that a complex system can be kept operating indefinitely with scheduled maintenance and emergency repair using a stock of spare parts, as long as the spare parts are not depleted. This assumption seems justified for well-tested, widely used, long operational systems with a multigenerational history of failure, redesign, and reliability growth. It seems doubtful that newer, relatively untried, high technology space systems can always be repaired. We cannot assume space systems will have a low rate of random failures that can all be repaired with a few identical spares. New untried systems usually have a high initial failure rate, called infant mortality, due to errors in requirements, design, parts, materials, and operations planning. These problems can cause groups of related failures called Common Cause Failures (CCFs). The practical definition of a CCF is any failure mode that cannot be cured using identical redundant systems or spare parts. Systems with CCFs may fail repeatedly for the same reason. Can a life support system be kept operating on the way to Mars using only redundant systems and spare parts? The failure history of International Space Station (ISS) life support systems suggests that CCFs are likely to occur and will probably require design changes rather than being reparable with spare parts.
Mars↗
A Novel Solution-Technique Applied to a Novel WAAS Architecture
The Federal Aviation Administration has embarked on an historic task of modernizing and significantly improving the national air transportation system. One system that uses the Global Positioning System (GPS) to determine aircraft navigational information is called the Wide Area Augmentation System (WAAS). This paper describes a reliability assessment of one candidate system architecture for the WAAS. A unique aspect of this study regards the modeling and solution of a candidate system that allows a novel cold sparing scheme. The cold spare is a WAAS communications satellite that is fabricated and launched after a predetermined number of orbiting satellite failures have occurred and after some stochastic fabrication time transpires. Because these satellites are complex systems with redundant components, they exhibit an increasing failure rate with a Weibull time to failure distribution. Moreover, the cold spare satellite build-time is Weibull and upon launch is considered to be a good-as-new system with an increasing failure rate and a Weibull time to failure distribution as well. The reliability model for this system is non-Markovian because three distinct system clocks are required: the time to failure of the orbiting satellites, the build time for the cold spare, and the time to failure for the launched spare satellite. A powerful dynamic fault tree modeling notation and Monte Carlo simulation technique with importance sampling are shown to arrive at a reliability prediction for a 10 year mission.
Bavuso, J.↗
Ultra Reliable Closed Loop Life Support for Long Space Missions
Spacecraft human life support systems can achieve ultra reliability by providing sufficient spares to replace all failed components. The additional mass of spares for ultra reliability is approximately equal to the original system mass, provided that the original system reliability is not too low. Acceptable reliability can be achieved for the Space Shuttle and Space Station by preventive maintenance and by replacing failed units. However, on-demand maintenance and repair requires a logistics supply chain in place to provide the needed spares. In contrast, a Mars or other long space mission must take along all the needed spares, since resupply is not possible. Long missions must achieve ultra reliability, a very low failure rate per hour, since they will take years rather than weeks and cannot be cut short if a failure occurs. Also, distant missions have a much higher mass launch cost per kilogram than near-Earth missions. Achieving ultra reliable spacecraft life support systems with acceptable mass will require a well-planned and extensive development effort. Analysis must determine the reliability requirement and allocate it to subsystems and components. Ultra reliability requires reducing the intrinsic failure causes, providing spares to replace failed components and having "graceful" failure modes. Technologies, components, and materials must be selected and designed for high reliability. Long duration testing is needed to confirm very low failure rates. Systems design should segregate the failure causes in the smallest, most easily replaceable parts. The system must be designed, developed, integrated, and tested with system reliability in mind. Maintenance and reparability of failed units must not add to the probability of failure. The overall system must be tested sufficiently to identify any design errors. A program to develop ultra reliable space life support systems with acceptable mass should start soon since it must be a long term effort.
Jones, Harry W.↗
Supportability for Beyond Low Earth Orbit Missions
Exploration beyond Low Earth Orbit (LEO) presents many unique challenges that will require changes from current Supportability approaches. Currently, the International Space Station (ISS) is supported and maintained through a series of preplanned resupply flights, on which spare parts, including some large, heavy Orbital Replacement Units (ORUs), are delivered to the ISS. The Space Shuttle system provided for a robust capability to return failed components to Earth for detailed examination and potential repair. Additionally, as components fail and spares are not already on-orbit, there is flexibility in the transportation system to deliver those required replacement parts to ISS on a near term basis. A similar concept of operation will not be feasible for beyond LEO exploration. The mass and volume constraints of the transportation system and long envisioned mission durations could make it difficult to manifest necessary spares. The supply of on-demand spare parts for missions beyond LEO will be very limited or even non-existent. In addition, the remote nature of the mission, the design of the spacecraft, and the limitations on crew capabilities will all make it more difficult to maintain the spacecraft. Alternate concepts of operation must be explored in which required spare parts, materials, and tools are made available to make repairs; the locations of the failures are accessible; and the information needed to conduct repairs is available to the crew. In this paper, ISS heritage information is presented along with a summary of the challenges of beyond LEO missions. A number of Supportability issues are discussed in relation to human exploration beyond LEO. In addition, the impacts of various Supportability strategies will be discussed. Any measure that can be incorporated to reduce risk and improve mission success should be evaluated to understand the advantages and disadvantages of implementing those measures. Finally, an effort to model and evaluate Supportability for beyond LEO missions will be described.
Crillo, William M.↗
ADEPT SR-1 Development and Testing
The Adaptable Deployable Entry and Placement Technology (ADEPT) Sounding Rocket One (SR-1) fight test will be the first sub-orbital flight of Nano-ADEPT. Nano-ADEPT is a deployable heatshield for secondary payload missions desiring to re-enter the Earth's atmosphere or deliver small science payloads to Mars or Venus. Two units have been built and tested in preparation of launch: one designated the "Spare" unit and one the "Flight" unit. The general development approach has been to perform all procedures on the Spare prior to performing them on Flight. This approach has served the project well, allowing for procedures to be rapidly developed and tested on spare hardware where mistakes are less consequential. Conversely, when schedule constraints have come up, the approach has allowed the project to rapidly pivot to an approach where Flight drives the critical path rather than Spare. This approach has enabled relatively rapid development of Flight where technical risk is balanced with schedule realism. This presentation will describe the various tests that have been performed on Nano-ADEPT Spare and Flight units to prepare for the sub-orbital flight. The purpose is to communicate the development approach we took for this low-cost, moderate-risk flight test and hopefully engage the EDL community in a wider discussion of risk-balanced approaches toward flight hardware development of secondary payload atmospheric entry systems.
Smith, Brandon↗
The case for a centralized repair depot for Space Shuttle
The first priority of the NSTS program is to make the Space Shuttle system fully operational and cost effective in providing routine access to space. In support of this priority an integrated logistics support system was planned, structured and is being implemented to support a launch-on-time goal of 95 percent. In achieving a 95 percent spares 'fill rate' in an environment of small fleet size, highly unique and high cost assets, significant spares cost can be incurred. A major portion of these costs are for the additional spares required when repair or acquisition times are lengthy. This paper provides a fundamental analysis of the costs and other factors involved in the spare and repair process and provides an optimized cost and process solution for the Space Shuttle program - a centralized repair depot located at KSC.
Enlow, R. D.↗
Reconfigurable tree architectures using subtree oriented fault tolerance
An approach to the design of reconfigurable tree architecture is presented in which spare processors are allocated at the leaves. The approach is unique in that spares are associated with subtrees and sharing of spares between these subtrees can occur. The Subtree Oriented Fault Tolerance (SOFT) approach is more reliable than previous approaches capable of tolerating link and switch failures for both single chip and multichip tree implementations while reducing redundancy in terms of both spare processors and links. VLSI layout is 0(n) for binary trees and is directly extensible to N-ary trees and fault tolerance through performance degradation.
Lowrie, Matthew B.↗
Reconfigurable tree architectures using subtree oriented fault tolerance
An approach to the design of reconfigurable tree architectures is presented in which spare processors are allocated at the leaves. The approach is unique in that spares are associated with subtrees, and sharing of spares between these subtrees can occur. The subtree-oriented fault-tolerance approach is more reliable than previous approaches capable of tolerating link and switch failures for both single-chip and multichip tree implementations while reducing redundancy in terms of both spare processors and links. VLSI layout is O(n) for binary trees and is directly extensible to N-ary trees and fault tolerance through performance degradation.
Lowrie, Matthew B.↗
Intelligent Systems for Self-Healing Electronics
For long duration missions it is imperative to be able to monitor and record critical information. The data acquisition systems used must therefore be fault tolerant. This usually meant having redundant copies of critical channels. Since each channel usually consists of various components, the parts count, cost, weight and complexity of the system could be very high. The Advanced Data Acquisition System (ADAS) has been developed as a proof of concept. The purpose was to demonstrate an architecture where individual spare parts can replace defective ones to repair a channel. By so doing entire channels do not need replication. This reduces the need of total redundancy and reduces the parts count. This has the added feature that in addition to spare parts, good components of a failed channel can be used as spares in another channel. In addition to reducing parts count and cost, this configuration, with an intelligent decision maker, can improve the reliability of the overall system. Another unique feature of ADAS is that it uses reconfigurable analog filters. These components can be programmed, by the smart system to meet the specific needs of the part they are to replace. This way one part can serve as spare for many different components. The hardware was built and now serves as a platform for developing intelligent algorithms. Another related project was a wireless data acquisition system. I was invited to participate in the meetings and issue suggestions. A brief description of this system will also be included.
Latino, Carl D.↗