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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 91 records · Page 5

Systems Health Monitoring: Integrating FMEA into Bayesian Networks

The foreseeable high traffic density suggests that a large number of electric propulsion systems will enter the airspace, and that they will also operate at high frequency, e.g., large number of take offs and landings per unit time. The reliability of such critical systems is therefore key to ensure high safety standards in the low-altitude airspace. Diagnostic systems, which aim at identifying incipient faults, can mitigate unexpected failures or lower-than-expected reliability by performing early fault detection by monitoring the systems. A key element of fault diagnosis is fault detection and isolation (FDI), which complexity increases with the complexity of the system itself, namely the number of subsystems and components, interactions among sub-systems, and the number of sensors available. The proposed approach leverages combination of failure mode and effect analysis (FMEA) integrated with Bayesian networks, thus introducing dependability structures into a diagnostic framework to aid FDI. Faults and failure events from the FMEA are mapped within a Bayesian network, where network edges replicate the links embedded within FMEAs. The integrated framework enables the fault isolation process by identifying the probability of occurrence of specific faults or root causes given evidence observed through sensor signals. In this work, sub systems of Urban Air Mobility (UAM) type vehicle like avionics, structures, power-train etc. are taken into account to show the approach at the system level. This work integrates early design phase in the development of UAM type vehicles with diagnostic tools, which are often developed later in the product life-cycle, or retrofitted at a later time on systems. Failure mode and effect analysis (FMEA) derived for the system in the design phase is embedded within a Bayesian network (BN).

UAM↗

Enhanced Schapery Theory Software Development for Modeling Failure of Fiber-Reinforced Laminates

Progressive damage and failure analysis (PDFA) tools are needed to predict the nonlinear response of advanced fiber-reinforced composite structures. Predictive tools should incorporate the underlying physics of the damage and failure mechanisms observed in the composite, and should utilize as few input parameters as possible. The purpose of the Enhanced Schapery Theory (EST) was to create a PDFA tool that operates in conjunction with a commercially available finite element (FE) code (Abaqus). The tool captures the physics of the damage and failure mechanisms that result in the nonlinear behavior of the material, and the failure methodology employed yields numerical results that are relatively insensitive to changes in the FE mesh. The EST code is written in Fortran and compiled into a static library that is linked to Abaqus. A Fortran Abaqus UMAT material subroutine is used to facilitate the communication between Abaqus and EST. A clear distinction between damage and failure is imposed. Damage mechanisms result in pre-peak nonlinearity in the stress strain curve. Four internal state variables (ISVs) are utilized to control the damage and failure degradation. All damage is said to result from matrix microdamage, and a single ISV marks the micro-damage evolution as it is used to degrade the transverse and shear moduli of the lamina using a set of experimentally obtainable matrix microdamage functions. Three separate failure ISVs are used to incorporate failure due to fiber breakage, mode I matrix cracking, and mode II matrix cracking. Failure initiation is determined using a failure criterion, and the evolution of these ISVs is controlled by a set of traction-separation laws. The traction separation laws are postulated such that the area under the curves is equal to the fracture toughness of the material associated with the corresponding failure mechanism. A characteristic finite element length is used to transform the traction-separation laws into stress-strain laws. The ISV evolution equations are derived in a thermodynamically consistent manner by invoking the stationary principle on the total work of the system with respect to each ISV. A novel feature is the inclusion of both pre-peak damage and appropriately scaled, post-peak strain softening failure. Also, the characteristic elements used in the failure degradation scheme are calculated using the element nodal coordinates, rather than simply the square root of the area of the element.

Pineda, Evan J.↗

Algorithm For Control Of Underactuated Manipulators

Algorithm for improved control of underactuated multiple-link robotic manipulators developed via spatial-algebra-operator approach. Aspects of this approach described in several previous articles in NASA Tech Briefs-most recently "Robot Control Based on Spatial-Operator Algebra" (NPO-17918). Underactuated manipulator has fewer actuators than it has degrees of freedom. Complexity of underactuated systems managed by unified analysis. It has implications for fault-tolerant control, and many practical manipulators underactuated. Examples include manipulators with flexible joints and/or flexible links; space/underwater robots; manipulators that operate with some actuators that turned off because of failure or because of need to conserve energy; manipulators that grasp objects loosely, and manipulators that grasp objects with internal degrees of freedom (e.g., plungers, rollers).

Jain, Abhinandan↗

Design and implementation of a status at a glance user interface for a power distribution expert system

A user interface to the power distribution expert system for Space Station Freedom is discussed. The importance of features which simplify assessing system status and which minimize navigating through layers of information are examined. Design rationale and implementation choices are also presented. The amalgamation of such design features as message linking arrows, reduced information content screens, high salience anomaly icons, and color choices with failure detection and diagnostic explanation from an expert system is shown to provide an effective status-at-a-glance monitoring system for power distribution. This user interface design offers diagnostic reasoning without compromising the monitoring of current events. The display can convey complex concepts in terms that are clear to its users.

Liberman, Eugene M.↗

A Comparison of Single-Cycle Versus Multiple-Cycle Proof Testing Strategies

Single-cycle and multiple-cycle proof testing (SCPT and MCPT) strategies for reusable aerospace propulsion system components are critically evaluated and compared from a rigorous elastic-plastic fracture mechanics perspective. Earlier MCPT studies are briefly reviewed. New J-integral estimation methods for semi-elliptical surface cracks and cracks at notches are derived and validated. Engineering methods are developed to characterize crack growth rates during elastic-plastic fatigue crack growth (FCG) and the tear-fatigue interaction near instability. Surface crack growth experiments are conducted with Inconel 718 to characterize tearing resistance, FCG under small-scale yielding and elastic-plastic conditions, and crack growth during simulated MCPT. Fractography and acoustic emission studies provide additional insight. The relative merits of SCPT and MCPT are directly compared using a probabilistic analysis linked with an elastic-plastic crack growth computer code. The conditional probability of failure in service is computed for a population of components that have survived a previous proof test, based on an assumed distribution of initial crack depths. Parameter studies investigate the influence of proof factor, tearing resistance, crack shape, initial crack depth distribution, and notches on the MCPT vs. SCPT comparison. The parameter studies provide a rational basis to formulate conclusions about the relative advantages and disadvantages of SCPT and MCPT. Practical engineering guidelines are proposed to help select the optimum proof test protocol in a given application.

McClung, R. C.↗

A Comparison of Single-Cycle Versus Multiple-Cycle Proof Testing Strategies

Single-cycle and multiple-cycle proof testing (SCPT and MCPT) strategies for reusable aerospace propulsion system components are critically evaluated and compared from a rigorous elastic-plastic fracture mechanics perspective. Earlier MCPT studies are briefly reviewed. New J-integral estimation methods for semi-elliptical surface cracks and cracks at notches are derived and validated. Engineering methods are developed to characterize crack growth rates during elastic-plastic fatigue crack growth (FCG) and the tear-fatigue interaction near instability. Surface crack growth experiments are conducted with Inconel 718 to characterize tearing resistance, FCG under small-scale yielding and elastic-plastic conditions, and crack growth during simulated MCPT. Fractography and acoustic emission studies provide additional insight. The relative merits of SCPT and MCPT are directly compared using a probabilistic analysis linked with an elastic-plastic crack growth computer code. The conditional probability of failure in service is computed for a population of components that have survived a previous proof test, based on an assumed distribution of initial crack depths. Parameter studies investigate the influence of proof factor, tearing resistance, crack shape, initial crack depth distribution, and notches on the MCPT vs. SCPT comparison. The parameter studies provide a rational basis to formulate conclusions about the relative advantages and disadvantages of SCPT and MCPT. Practical engineering guidelines are proposed to help select the optimum proof test protocol in a given application.

McClung, R. C.↗

A Comparison of Single-Cycle Versus Multiple-Cycle Proof Testing Strategies

Single-cycle and multiple-cycle proof testing (SCPT and MCPT) strategies for reusable aerospace propulsion system components are critically evaluated and compared from a rigorous elastic-plastic fracture mechanics perspective. Earlier MCPT studies are briefly reviewed. New J-integral estimation methods for semielliptical surface cracks and cracks at notches are derived and validated. Engineering methods are developed to characterize crack growth rates during elastic-plastic fatigue crack growth (FCG) and the tear-fatigue interaction near instability. Surface crack growth experiments are conducted with Inconel 718 to characterize tearing resistance, FCG under small-scale yielding and elastic-plastic conditions, and crack growth during simulated MCPT. Fractography and acoustic emission studies provide additional insight. The relative merits of SCPT and MCPT are directly compared using a probabilistic analysis linked with an elastic-plastic crack growth computer code. The conditional probability of failure in service is computed for a population of components that have survived a previous proof test, based on an assumed distribution of initial crack depths. Parameter studies investigate the influence of proof factor, tearing resistance, crack shape, initial crack depth distribution, and notches on the MCPT versus SCPT comparison. The parameter studies provide a rational basis to formulate conclusions about the relative advantages and disadvantages of SCPT and MCPT. Practical engineering guidelines are proposed to help select the optimum proof test protocol in a given application.

McClung, R. C.↗

Space Launch System Implementation of Adaptive Augmenting Control

Given the complex structural dynamics, challenging ascent performance requirements, and rigorous flight certification constraints owing to its manned capability, the NASA Space Launch System (SLS) launch vehicle requires a proven thrust vector control algorithm design with highly optimized parameters to provide stable and high-performance flight. On its development path to Preliminary Design Review (PDR), the SLS flight control system has been challenged by significant vehicle flexibility, aerodynamics, and sloshing propellant. While the design has been able to meet all robust stability criteria, it has done so with little excess margin. Through significant development work, an Adaptive Augmenting Control (AAC) algorithm has been shown to extend the envelope of failures and flight anomalies the SLS control system can accommodate while maintaining a direct link to flight control stability criteria such as classical gain and phase margin. In this paper, the work performed to mature the AAC algorithm as a baseline component of the SLS flight control system is presented. The progress to date has brought the algorithm design to the PDR level of maturity. The algorithm has been extended to augment the full SLS digital 3-axis autopilot, including existing load-relief elements, and the necessary steps for integration with the production flight software prototype have been implemented. Several updates which have been made to the adaptive algorithm to increase its performance, decrease its sensitivity to expected external commands, and safeguard against limitations in the digital implementation are discussed with illustrating results. Monte Carlo simulations and selected stressing case results are also shown to demonstrate the algorithm's ability to increase the robustness of the integrated SLS flight control system.

Wall, John H.↗

Multiscale Failure Analysis of Laminated Composite Panels Subjected to Blast Loading Using FEAMAC/Explicit

This preliminary report demonstrates the capabilities of the recently developed software implementation that links the Generalized Method of Cells to explicit finite element analysis by extending a previous development which tied the generalized method of cells to implicit finite elements. The multiscale framework, which uses explicit finite elements at the global-scale and the generalized method of cells at the microscale is detailed. This implementation is suitable for both dynamic mechanics problems and static problems exhibiting drastic and sudden changes in material properties, which often encounter convergence issues with commercial implicit solvers. Progressive failure analysis of stiffened and un-stiffened fiber-reinforced laminates subjected to normal blast pressure loads was performed and is used to demonstrate the capabilities of this framework. The focus of this report is to document the development of the software implementation; thus, no comparison between the results of the models and experimental data is drawn. However, the validity of the results are assessed qualitatively through the observation of failure paths, stress contours, and the distribution of system energies.

Pineda, Evan J.↗

Apollo 15 main-parachute failure

In the investigation of the failure of one of the three main parachutes of the Apollo 15 spacecraft, which collapsed at approximately 1825 meters after operating properly from deployment at 3050 meters, three conditions considered to be possible causes of the failure were produced. The suspect conditions were the proximity of the forward heat shield that passed the spacecraft at approximately 1825 meters, the dumping of the reaction control system hypergolic propellants at approximately 1825 meters, and the failing of a riser link found on a recovered parachute. (The failed parachute was not recovered). The remaining two parachutes functioned as planned and averted a catastrophic failure. The conclusions concerning the cause of the failure are discussed.

Arabian, D. D.↗

Remote Maintenance Monitoring

Automated system gives new life to aging network of computers. Remote maintenance monitoring system developed to diagnose problems in large distributed computer network. Consists of data links, displays, controls, software, and more than 200 computers. Uses sensors to collect data on failures and expert system to examine data, diagnose causes of failures, and recommend cures. Designed to be retrofitted into launch processing system at Kennedy Space Center. Reduces downtime, lowers workload and expense of maintenance, and makes network less dependent on human expertise.

Owens, Richard C.↗

Space Flight Applications of Optical Fiber; 30 Years of Space Flight Success

For over thirty years NASA has had success with space flight missions that utilize optical fiber component technology. One of the early environmental characterization experiments that included optical fiber was launched as the Long Duration Exposure Facility in 1978. Since then, multiple missions have launched with optical fiber components that functioned as expected, without failure throughout the mission life. The use of optical fiber in NASA space flight communications links and exploration and science instrumentation is reviewed.

Ott, Melanie N.↗

AirSTAR Hardware and Software Design for Beyond Visual Range Flight Research

The National Aeronautics and Space Administration (NASA) Airborne Subscale Transport Aircraft Research (AirSTAR) Unmanned Aerial System (UAS) is a facility developed to study the flight dynamics of vehicles in emergency conditions, in support of aviation safety research. The system was upgraded to have its operational range significantly expanded, going beyond the line of sight of a ground-based pilot. A redesign of the airborne flight hardware was undertaken, as well as significant changes to the software base, in order to provide appropriate autonomous behavior in response to a number of potential failures and hazards. Ground hardware and system monitors were also upgraded to include redundant communication links, including ADS-B based position displays and an independent flight termination system. The design included both custom and commercially available avionics, combined to allow flexibility in flight experiment design while still benefiting from tested configurations in reversionary flight modes. A similar hierarchy was employed in the software architecture, to allow research codes to be tested, with a fallback to more thoroughly validated flight controls. As a remotely piloted facility, ground systems were also developed to ensure the flight modes and system state were communicated to ground operations personnel in real-time. Presented in this paper is a general overview of the concept of operations for beyond visual range flight, and a detailed review of the airborne hardware and software design. This discussion is held in the context of the safety and procedural requirements that drove many of the design decisions for the AirSTAR UAS Beyond Visual Range capability.

Laughter, Sean↗

Space Launch System Implementation of Adaptive Augmenting Control

Given the complex structural dynamics, challenging ascent performance requirements, and rigorous flight certification constraints owing to its manned capability, the NASA Space Launch System (SLS) launch vehicle requires a proven thrust vector control algorithm design with highly optimized parameters to robustly demonstrate stable and high performance flight. On its development path to preliminary design review (PDR), the stability of the SLS flight control system has been challenged by significant vehicle flexibility, aerodynamics, and sloshing propellant dynamics. While the design has been able to meet all robust stability criteria, it has done so with little excess margin. Through significant development work, an adaptive augmenting control (AAC) algorithm previously presented by Orr and VanZwieten, has been shown to extend the envelope of failures and flight anomalies for which the SLS control system can accommodate while maintaining a direct link to flight control stability criteria (e.g. gain & phase margin). In this paper, the work performed to mature the AAC algorithm as a baseline component of the SLS flight control system is presented. The progress to date has brought the algorithm design to the PDR level of maturity. The algorithm has been extended to augment the SLS digital 3-axis autopilot, including existing load-relief elements, and necessary steps for integration with the production flight software prototype have been implemented. Several updates to the adaptive algorithm to increase its performance, decrease its sensitivity to expected external commands, and safeguard against limitations in the digital implementation are discussed with illustrating results. Monte Carlo simulations and selected stressing case results are shown to demonstrate the algorithm's ability to increase the robustness of the integrated SLS flight control system.

VanZwieten, Tannen S.↗

Adaptive fault-tolerant routing in hypercube multicomputers

A connected hypercube with faulty links and/or nodes is called an injured hypercube. To enable any non-faulty node to communicate with any other non-faulty node, information on component failures has to be made available to non-faulty nodes so as to route messages around the faulty components. A distributed adaptive fault tolerant routing scheme is proposed in which each node is required to know only the condition of its own links. This scheme is shown to be capable of routing messages successfully as long as the number of faulty components is less than n (the dimension of the hypercube), and to route messages via shortest paths with a rather high probability. A second routing scheme based on depth-first search is proposed which works in the presence of an arbitrary number of faulty components; however, the paths chosen by this may not always be the shortest. To guarantee shortest paths, every mode must be given information beyond that on its own links; the additional information to be kept at each node for shortest-path routing is determined. Several examples are given to illustrate the results.

Chen, Ming-Syan↗

Earthly Considerations on Mars

When it came time to contact my research subjects on the Orbiter and Lander projects, I made it clear that I wasn't interested in finger pointing and I wasn't looking to blame anyone for failures. I explained that I was studying the strategic design of each project, i. e., the grouping, linking and alignment of the project. I wanted to look at the political environment to see how the goals and interests of stakeholders affected the outcomes, and I wanted to understand the working culture of each project.

Shaw, Robert J.↗

Building a Database for a Quantitative Model

A database can greatly benefit a quantitative analysis. The defining characteristic of a quantitative risk, or reliability, model is the use of failure estimate data. Models can easily contain a thousand Basic Events, relying on hundreds of individual data sources. Obviously, entering so much data by hand will eventually lead to errors. Not so obviously entering data this way does not aid linking the Basic Events to the data sources. The best way to organize large amounts of data on a computer is with a database. But a model does not require a large, enterprise-level database with dedicated developers and administrators. A database built in Excel can be quite sufficient. A simple spreadsheet database can link every Basic Event to the individual data source selected for them. This database can also contain the manipulations appropriate for how the data is used in the model. These manipulations include stressing factors based on use and maintenance cycles, dormancy, unique failure modes, the modeling of multiple items as a single "Super component" Basic Event, and Bayesian Updating based on flight and testing experience. A simple, unique metadata field in both the model and database provides a link from any Basic Event in the model to its data source and all relevant calculations. The credibility for the entire model often rests on the credibility and traceability of the data.

Kahn, C. Joseph↗

Analysis of dynamic stall using unsteady boundary-layer theory

The unsteady turbulent boundary layer and potential flow about a pitching airfoil are analyzed using numerical methods to determine the effect of pitch rate on the delay in forward movement of the rear flow reversal point. An explicit finite difference scheme is used to integrate the unsteady boundary layer equations, which are coupled at each instant of time to a fully unsteady and nonlinear potential flow analysis. A substantial delay in forward movement of the reversal point is demonstrated with increasing pitch rate, and it is shown that the delay results partly from the alleviation of the gradients in the potential flow, and partly from the effects of unsteadiness in the boundary layer itself. The predicted delay in flow-reversal onset, and its variation with pitch rate, are shown to be in reasonable agreement with experimental data relating to the delay in dynamic stall. From the comparisons it can be concluded (a) that the effects of time-dependence are sufficient to explain the failure of the boundary layer to separate during the dynamic overshoot, and (b) that there may be some link between forward movement of the reversal point and dynamic stall.

Scruggs, R. M.↗