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NASA NTRS2018

Stirling Convertor Controller Development at NASA Glenn Research Center

For nearly two decades, NASA Glenn Research Center has been supporting the development of radioisotope power systems (RPS). NASA desires higher conversion efficiency RPS options that are reliable and robust with long-life design. Dynamic conversion, such as Stirling and Brayton, offer the potential for higher conversion efficiencies than current RPS but have yet to be demonstrated in a flight application. The RPS program sent out a solicitation to investigate options for dynamic conversion technologies. As a result of this solicitation, four dynamic power convertor (DPC) technologies were selected for design and three are proceeding to the fabrication phase of prototype dynamic convertors. One lesson learned from the Advanced Stirling Radioisotope Generator (ASRG) project is that controller development should be coordinated with the development of a dynamic convertor. As a result of this, Glenn has been utilizing hardware from past Stirling convertor projects, including that of the ASRG, to support controller development for the DPCs. Glenn has developed a strong knowledge base on both analog and digital Stirling DPC controllers and will continue to expand and apply that knowledge to the DPCs. Over the past 15 years, controllers were developed at Glenn, at Lockheed Martin (LM), and by the Johns Hopkins University Applied Physics Laboratory (APL). Various generations of the controllers have been developed as lessons were learned through various component- and system-level tests. Some of the tests performed were fault tolerance, flight acceptance vibration, electromagnetic interference (EMI), spacecraft integration, and extended operation. The fault tolerance test characterized the controller’s ability to handle various fault conditions, including high or low bus power consumption, total open load or short circuit, and replacing a failed controller card while the backup maintains control of the Stirling convertor. The vibration test confirms the controller’s ability to control an Advanced Stirling Convertor (ASC) during launch. The EMI test characterized the alternating-current (AC) and direct-current (DC) magnetic and electric fields emitted by the single ASC and if the controller has an impact on the radiated EMI. Spacecraft integration testing in the Radioisotope Power Systems (RPS), System Integration Laboratory (RSIL) provided insight into the electrical interactions between the representative RPS, its associated control schemes, and realistic electric system loads. The extended operation test allows data to be collected over a period of thousands of hours to obtain long-term performance data of the system. This paper describes the history of controller development at Glenn, tests performed on these controllers, and lessons learned.

Dugala, Gina M.↗

NASA NTRS1986

Flight control system development and flight test experience with the F-111 mission adaptive wing aircraft

The wing on the NASA F-111 transonic aircraft technology airplane was modified to provide flexible leading and trailing edge flaps. This wing is known as the mission adaptive wing (MAW) because aerodynamic efficiency can be maintained at all speeds. Unlike a conventional wing, the MAW has no spoilers, external flap hinges, or fairings to break the smooth contour. The leading edge flaps and three-segment trailing edge flaps are controlled by a redundant fly-by-wire control system that features a dual digital primary system architecture providing roll and symmetric commands to the MAW control surfaces. A segregated analog backup system is provided in the event of a primary system failure. This paper discusses the design, development, testing, qualification, and flight test experience of the MAW primary and backup flight control systems.

Larson, R. R.↗

NASA NTRS1986

Flight control system development and flight test experience with the F-111 mission adaptive wing aircraft

Larson, R. R.↗

NASA NTRS1992

Mechanical Backup For Fly-By-Wire Control System

Mechanical device eliminates need for redundant fly-by-wire subsystems. Main components are two linkages. One connected to control column in conventional, reversible control system. Other slides inside first linkage and connected to pilot's control wheel. In addition to aircraft applications, design used in control systems in which computer control desirable but safety backup systems required; for example, in boat rudders, engine controls in boats and automobiles, and controls in construction equipment.

Stewart, Eric C.↗

NASA NTRS1993

Design, analysis, and control of large transport aircraft utilizing engine thrust as a backup system for the primary flight controls

A review of accidents that involved the loss of hydraulic flight control systems serves as an introduction to this project. In each of the accidents--involving transport aircraft such as the DC-10, the C-5A, the L-1011, and the Boeing 747--the flight crew attempted to control the aircraft by means of thrust control. Although these incidents had tragic endings, in the absence of control power due to primary control system failure, control power generated by selective application of engine thrust has proven to be a viable alternative. NASA Dryden has demonstrated the feasibility of controlling an aircraft during level flight, approach, and landing conditions using an augmented throttles-only control system. This system has been successfully flown in the flight test simulator for the B-720 passenger transport and the F-15 air superiority fighter and in actual flight tests for the F-15 aircraft. The Douglas Aircraft Company is developing a similar system for the MD-11 aircraft. The project's ultimate goal is to provide data for the development of thrust control systems for mega-transports (600+ passengers).

Gerren, Donna S.↗

NASA NTRS1979

Flight control systems development of highly maneuverable aircraft technology /HiMAT/ vehicle

The highly maneuverable aircraft technology (HiMAT) program was conceived to demonstrate advanced technology concepts through scaled-aircraft flight tests using a remotely piloted technique. Closed-loop primary flight control is performed from a ground-based cockpit, utilizing a digital computer and up/down telemetry links. A backup flight control system for emergency operation resides in an onboard computer. The onboard systems are designed to provide fail-operational capabilities and utilize two microcomputers, dual uplink receiver/decoders, and redundant hydraulic actuation and power systems. This paper discusses the design and validation of the primary and backup digital flight control systems as well as the unique pilot and specialized systems interfaces.

Petersen, K. L.↗

NASA NTRS1975

Space Shuttle flight control system

The Space Shuttle is a control stabilized vehicle with control provided by an all digital, fly-by-wire flight control system. This paper gives a description of the several modes of flight control which correspond to the Shuttle mission phases. These modes are ascent flight control (including open loop first stage steering, the use of four computers operating in parallel and inertial guidance sensors), on-orbit flight control (with a discussion of reaction control, phase plane switching logic, jet selection logic, state estimator logic and OMS thrust vector control), entry flight control and TAEM (terminal area energy management to landing). Also discussed are redundancy management and backup flight control.

Klinar, W. J.↗

NASA NTRS1981

HiMAT onboard flight computer system architecture and qualification

Two highly maneuverable aircraft technology (HiMAT) remotely piloted research vehicles (RPRV's) are being flight tested at NASA Dryden Flight Research Center, Edwards, California, to demonstrate and evaluate a number of technological advances applicable to future fighter aircraft. Closed-loop primary flight control is performed from a ground-based cockpit utilizing a digital computer and up/down telemetry links. A backup flight control system for emergency operation resides in one of two onboard computers. Other functions of the onboard computer system are uplink processing, downlink processing, engine control, failure detection, and redundancy management. This paper describes the architecture, functions, and flight qualification of the HiMAT onboard flight computer systems.

Myers, A. F.↗

NASA NTRS2001

Integrated Neural Flight and Propulsion Control System

This paper describes an integrated neural flight and propulsion control system. which uses a neural network based approach for applying alternate sources of control power in the presence of damage or failures. Under normal operating conditions, the system utilizes conventional flight control surfaces. Neural networks are used to provide consistent handling qualities across flight conditions and for different aircraft configurations. Under damage or failure conditions, the system may utilize unconventional flight control surface allocations, along with integrated propulsion control, when additional control power is necessary for achieving desired flight control performance. In this case, neural networks are used to adapt to changes in aircraft dynamics and control allocation schemes. Of significant importance here is the fact that this system can operate without emergency or backup flight control mode operations. An additional advantage is that this system can utilize, but does not require, fault detection and isolation information or explicit parameter identification. Piloted simulation studies were performed on a commercial transport aircraft simulator. Subjects included both NASA test pilots and commercial airline crews. Results demonstrate the potential for improving handing qualities and significantly increasing survivability rates under various simulated failure conditions.

Kaneshige, John↗

NASA NTRS2005

AOCS Performance and Stability Validation for a 160-m Solar Sail with Control-Structure Interactions

Future solar sail missions, such as NASA's Solar Polar Imager Vision, will require sails with dimensions on the order of 50-500 m. We are examining a square sail design with moving mass (trim control mass, TCM) and quadrant rotation primary actuators plus pulsed plasma thrusters (PPTs) at the mast tips for backup attitude control. Quadrant rotation is achieved via roll stabilizer bars (RSB) at the mast tips. At these sizes, given the gossamer nature of the sail supporting structures, flexible modes may be low enough to interact with the control system, especially as these actuators are located on the flexible structure itself and not on the rigid core. This paper develops a practical analysis of the flexible interactions using state-space systems and modal data from finite element models of the system. Torsion and bending of the masts during maneuvers could significantly affect the function of the actuators while activation of the membrane modes could adversely affect the thrust vector direction and magnitude. Analysis of the RSB and TCM dynamics for developing high-fidelity simulations is included. For control analysis of the flexible system, standard finite-element models of the flexible sail body are loaded and the modal data is used to create a modal coordinate state-space system. Key parameters include which modes to include, which nodes are of interest for force inputs and displacement outputs, connecting nodes through which external forces and torques are applied from the flex body to the core, any nominal momentum in the system, and any steady rates. The system is linearized about the nominal attitude and rate. The state-space plant can then be analyzed with a state-space controller, and Bode, Nyquist, step and impulse responses generated. The approach is general for any rigid core with a flexible appendage. This paper develops a compensator for a simple two-mass flex system and extrapolates the results to the solar sail. A finite element model of the 20 m solar sail by ATK Space Systems, recently validated in ground tests, is used to demonstrate the sail analysis approach.

Wie, Bong↗

NASA NTRS1997

An Investigation of Nonlinear Controller for Propulsion Controlled Aircraft

Aircraft control systems are usually very reliable because of redundancy and multiple control surfaces. However, there are rare occasions when potentially disastrous flight control system failures do occur. At such times, the use of appropriate modulation of engine thrust to stabilize the aircraft may be the only chance of survival for the people aboard. In several cases where complete loss of control systems has occurred in multi-engine aircraft, pilots used the propulsion system to regain limited control of the aircraft with various degrees of success. In order to evaluate the feasibility of using only engine thrust modulation for emergency backup flight control, the NASA Dryden Flight Research Center has been conducting a series of analytical studies and flight tests on several different types of aircraft in a propulsion controlled aircraft (PCA) program. Simulation studies have included B-720, B-727, MD-11, C-402, C-17, F-18, and F-15, and flight tests have included B-747, B-777, MD-11, T-39, Lear 24, F-18, F-15, T-38, and PA-30. One objective was to determine the degree of control available with manual manipulation (open-loop) of the engine throttles. Flight tests and simulations soon showed that a closed loop controller could improve the chances of making a safe runway landing. The major work to date has concentrated on three aircraft (F-15, F-18, and the MD-11). Successful landings using PCA controllers were performed on the F-15 and MD-11 without the use of control surfaces. During the course of the research, some unique challenges have been identified. Compared to the conventional flight control surfaces, the engines are slow and have limited control effectiveness. Hence the ability of the system to promptly respond to aerodynamic changes is limited. Consequently, many nonlinear effects, which are easily accommodated by a conventional flight control system, become significant issues in the design of an effective controller when the engines are used as the only control effectors. A number of nonlinear behaviors observed during PCA flight tests, which are not meant to be exhaustive, are reviewed in the next section.

Lu, Ping↗

NASA NTRS1995

Design, analysis and control of large transports so that control of engine thrust can be used as a back-up of the primary flight controls

A propulsion controlled aircraft (PCA) system has been developed at NASA Dryden Flight Research Center at Edwards Air Force Base, California, to provide safe, emergency landing capability should the primary flight control system of the aircraft fail. As a result of the successful PCA work being done at NASA Dryden, this project investigated the possibility of incorporating the PCA system as a backup flight control system in the design of a large, ultra-high capacity megatransport in such a way that flight path control using only the engines is not only possible, but meets MIL-Spec Level 1 or Level 2 handling quality requirements. An 800 passenger megatransport aircraft was designed and programmed into the NASA Dryden simulator. Many different analysis methods were used to evaluate the flying qualities of the megatransport while using engine thrust for flight path control, including: (1) Bode and root locus plot analysis to evaluate the frequency and damping ratio response of the megatransport; (2) analysis of actual simulator strip chart recordings to evaluate the time history response of the megatransport; and (3) analysis of Cooper-Harper pilot ratings by two NaSA test pilots.

Roskam, Jan↗

NASA NTRS2006

TRMM On-Orbit Performance Re-Accessed After Control Change

The Tropical Rainfall Measuring Mission (TRMM) spacecraft, a joint mission between the U.S. and Japan, launched onboard an HI1 rocket on November 27,1997 and transitioned in August, 2001 from an average operating altitude of 350 kilometers to 402.5 kilometers. Due to problems using the Earth Sensor Assembly (ESA) at the higher altitude, TRMM switched to a backup attitude control mode. Prior to the orbit boost TRMM controlled pitch and roll to the local vertical using ESA measurements while using gyro data to propagate yaw attitude between yaw updates from the Sun sensors. After the orbit boost, a Kalman filter used 3-axis gyro data with Sun sensor and magnetometers to estimate onboard attitude. While originally intended to meet a degraded attitude accuracy of 0.7 degrees, the new control mode met the original 0.2 degree attitude accuracy requirement after improving onboard ephemeris prediction and adjusting the magnetometer calibration onboard. Independent roll attitude checks using a science instrument, the Precipitation Radar (PR) which was built in Japan, provided a novel insight into the pointing performance. The PR data helped identify the pointing errors after the orbit boost, track the performance improvements, and show subtle effects from ephemeris errors and gyro bias errors. It also helped identify average bias trends throughout the mission. Roll errors tracked by the PR from sample orbits pre-boost and post-boost are shown in Figure 1. Prior to the orbit boost the largest attitude errors were due to occasional interference in the ESA. These errors were sometime larger than 0.2 degrees in pitch and roll, but usually less, as estimated from a comprehensive review of the attitude excursions using gyro data. Sudden jumps in the onboard roll show up as spikes in the reported attitude since the control responds within tens of seconds to null the pointing error. The PR estimated roll tracks well with an estimate of the roll history propagated using gyro data. After the orbit boost, the attitude errors shown by the PR roll have a smooth sine-wave type signal because of the way that attitude errors propagate with the use of gyro data. Yaw errors couple at orbit period to roll with '/4 orbit lag. By tracking the amplitude, phase, and bias of the sinusoidal PR roll error signal, it was shown that the average pitch rotation axis tends to be offset from orbit normal in a direction perpendicular to the Sun direction, as shown in Figure 2 for a 200 day period following the orbit boost. This is a result of the higher accuracy and stability of the Sun sensor measurements relative to the magnetometer measurements used in the Kalman filter. In November, 2001 a magnetometer calibration adjustment was uploaded which improved the pointing performance, keeping the roll and yaw amplitudes within about 0.1 degrees. After the boost, onboard ephemeris errors had a direct effect on the pitch pointing, being used to compute the Earth pointing reference frame. Improvements after the orbit boost have kept the the onboard ephemeris errors generally below 20 kilometers. Ephemeris errors have secondary effects on roll and yaw, especially during high beta angle when pitch effects can couple into roll and yaw. This is illustrated in figure 3. The onboard roll bias trends as measured by PR data show correlations with the Kalman filter's gyro bias error. This particularly shows up after yaw turns (every 2 to 4 weeks) as shown in Figure 3, when a slight roll bias is observed while the onboard computed gyro biases settle to new values. As for longer term trends, the PR data shows that the roll bias was influenced by Earth horizon radiance effects prior to the boost, changing values at yaw turns, and indicated a long term drift as shown in Figure 4. After the boost, the bias variations were smaller and showed some possible correlation with solar beta angle, probably due to sun sensor misalignment effects.

Bilanow, Steve↗

NASA NTRS2006

TRMM On-Orbit Performance Reassessed After Control Change

The Tropical Rainfall Measuring Mission (TRMM) spacecraft, a joint mission between the U.S. and Japan, launched onboard an H-I1 rocket on November 27, 1997, and transitioned in August, 2001, from an average operating altitude of 350 kilometers to 402.5 kilometers. Due to problems using the Earth Sensor Assembly (ESA) at the higher altitude, TRMM switched to a backup attitude control mode. Prior to the orbit boost TRMM controlled pitch and roll to the local vertical using ESA measurements while using gyro data to propagate yaw attitude between yaw updates from the Sun sensors. After the orbit boost, a Kalman filter used 3-axis gyro data with Sun sensor and magnetometers to estimate onboard attitude. While originally intended to meet a degraded attitude accuracy of 0.7 degrees, the new control mode met the original 0.2 degree attitude accuracy requirement after improving onboard ephemeris prediction and adjusting the magnetometer calibration onboard. Independent roll attitude checks using a science instrument, the Precipitation Radar (PR) which was built in Japan, provided a novel insight into the pointing performance. The PR data helped identify the pointing errors after the orbit boost, track the performance improvements, and show subtle effects from ephemeris errors and gyro bias errors. It also helped identify average bias trends throughout the mission. Roll errors tracked by the PR from sample orbits pre-boost and post-boost are shown in Figure 1. Prior to the orbit boost, the largest attitude errors were due to occasional interference in the ESA. These errors were sometime larger than 0.2 degrees in pitch and roll, but usually less, as estimated from a comprehensive review of the attitude excursions using gyro data. Sudden jumps in the onboard roll show up as spikes in the reported attitude since the control responds within tens of seconds to null the pointing error. The PR estimated roll tracks well with an estimate of the roll history propagated using gyro data. After the orbit boost, the attitude errors shown by the PR roll have a smooth sine-wave type signal because of the way that attitude errors propagate with the use of gyro data. Yaw errors couple at orbit period to roll with 1/4 orbit lag. By tracking the amplitude, phase, and bias of the sinusoidal PR roll error signal, it was shown that the average pitch rotation axis tends to be offset from orbit normal in a direction perpendicular to the Sun direction, as shown in Figure 2 for a 200 day period following the orbit boost. This is a result of the higher accuracy and stability of the Sun sensor measurements relative to the magnetometer measurements used in the Kalman filter. In November, 2001 a magnetometer calibration adjustment was uploaded which improved the pointing performance, keeping the roll and yaw amplitudes within about 0.1 degrees.

Bilanow, Stephen↗

NASA NTRS2013

Small Radioisotope Power System Testing at NASA Glenn Research Center

In April 2009, NASA Glenn Research Center (GRC) formed an integrated product team (IPT) to develop a Small Radioisotope Power System (SRPS) utilizing a single Advanced Stirling Convertor (ASC) with passive balancer. A single ASC produces approximately 80 We making this system advantageous for small distributed lunar science stations. The IPT consists of Sunpower, Inc., to provide the single ASC with a passive balancer, The Johns Hopkins University Applied Physics Laboratory (JHUAPL) to design an engineering model Single Convertor Controller (SCC) for an ASC with a passive balancer, and NASA GRC to provide technical support to these tasks and to develop a simulated lunar lander test stand. The single ASC with a passive balancer, simulated lunar lander test stand, and SCC were delivered to GRC and were tested as a system. The testing sequence at GRC included SCC fault tolerance, integration, electromagnetic interference (EMI), vibration, and extended operation testing. The SCC fault tolerance test characterized the SCCs ability to handle various fault conditions, including high or low bus power consumption, total open load or short circuit, and replacing a failed SCC card while the backup maintains control of the ASC. The integrated test characterized the behavior of the system across a range of operating conditions, including variations in cold-end temperature and piston amplitude, including the emitted vibration to both the sensors on the lunar lander and the lunar surface. The EMI test characterized the AC and DC magnetic and electric fields emitted by the SCC and single ASC. The vibration test confirms the SCCs ability to control the single ASC during launch. The extended operation test allows data to be collected over a period of thousands of hours to obtain long term performance data of the ASC with a passive balancer and the SCC. This paper will discuss the results of each of these tests.

Vibration↗

NASA NTRS2011

Wallops Ship Surveillance System

Approved as a Wallops control center backup system, the Wallops Ship Surveillance Software is a day-of-launch risk analysis tool for spaceport activities. The system calculates impact probabilities and displays ship locations relative to boundary lines. It enables rapid analysis of possible flight paths to preclude the need to cancel launches and allow execution of launches in a timely manner. Its design is based on low-cost, large-customer- base elements including personal computers, the Windows operating system, C/C++ object-oriented software, and network interfaces. In conformance with the NASA software safety standard, the system is designed to ensure that it does not falsely report a safe-for-launch condition. To improve the current ship surveillance method, the system is designed to prevent delay of launch under a safe-for-launch condition. A single workstation is designated the controller of the official ship information and the official risk analysis. Copies of this information are shared with other networked workstations. The program design is divided into five subsystems areas: 1. Communication Link -- threads that control the networking of workstations; 2. Contact List -- a thread that controls a list of protected item (ocean vessel) information; 3. Hazard List -- threads that control a list of hazardous item (debris) information and associated risk calculation information; 4. Display -- threads that control operator inputs and screen display outputs; and 5. Archive -- a thread that controls archive file read and write access. Currently, most of the hazard list thread and parts of other threads are being reused as part of a new ship surveillance system, under the SureTrak project.

Smith, Donna C.↗

NASA NTRS1968

Lunar module pilot control considerations

Lunar module backup guidance, navigation and pilot interfaces with control systems during lunar landing missions

Brickel, J. R.↗

NASA NTRS1972

Motion simulator study of longitudinal stability requirements for large delta wing transport airplanes during approach and landing with stability augmentation systems failed

A ground-based simulator investigation was conducted in preparation for and correlation with an-flight simulator program. The objective of these studies was to define minimum acceptable levels of static longitudinal stability for landing approach following stability augmentation systems failures. The airworthiness authorities are presently attempting to establish the requirements for civil transports with only the backup flight control system operating. Using a baseline configuration representative of a large delta wing transport, 20 different configurations, many representing negative static margins, were assessed by three research test pilots in 33 hours of piloted operation. Verification of the baseline model to be used in the TIFS experiment was provided by computed and piloted comparisons with a well-validated reference airplane simulation. Pilot comments and ratings are included, as well as preliminary tracking performance and workload data.

Snyder, C. T.↗