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The WFIRST Wide Field Instrument completed its Preliminary Design phase in June 2019. The current status, design overview, and open work planned for the Detailed Design phase are summarized.
The concept of integrated sustainable product design has recently emerged, aiming to incorporate downstream life cycle performance into the initial product design to enhance sustainability. Various sustainable product design tools based on life cycle assessment or quality function deployment have been established while the impact of reliability on circular practices has received limited attention. Recognizing the critical role of product reliability in post-design performance, this paper develops a product design optimization model that considers the warranty performance and the effect of end-of-use options. The model takes into account the effect of uncertain operating conditions on product reliability. Two optimization goals including the minimization of expected unit life cycle cost and environmental impact are achieved by the model. To demonstrate the benefits of the integrated approach, the model is applied to an electric motor design problem. The results highlight that integrating end-of-use options in the early design phase leads to adjustments in component selection and reliability design. Moreover, the circular utilization of used products enables cost savings throughout the product’s life cycle and contributes to environmental impact reduction. Finally, the study analyzes the effects of operating conditions, warranty policies, and take-back prices for used products on design decisions, providing valuable insights for product designers.
The United States National Aeronautics and Space Administration (NASA) is in the midst of a space exploration program called Constellation to send crew and cargo to the international Space Station, to the moon, and beyond. As part of the Constellation program, a new launch vehicle, Ares I, is being developed by NASA Marshall Space Flight Center. Designing a launch vehicle with high reliability and increased safety requires a significant effort in understanding design variability and design uncertainty at the various levels of the design (system, element, subsystem, component, etc.) and throughout the various design phases (conceptual, preliminary design, etc.). In a previous paper [1] we discussed a probabilistic functional failure analysis approach intended mainly to support system requirements definition, system design, and element design during the early design phases. This paper provides an overview of the application of probabilistic engineering methods to support the detailed subsystem/component design and development as part of the "Design for Reliability and Safety" approach for the new Ares I Launch Vehicle. Specifically, the paper discusses probabilistic engineering design analysis cases that had major impact on the design and manufacturing of the Space Shuttle hardware. The cases represent important lessons learned from the Space Shuttle Program and clearly demonstrate the significance of probabilistic engineering analysis in better understanding design deficiencies and identifying potential design improvement for Ares I. The paper also discusses the probabilistic functional failure analysis approach applied during the early design phases of Ares I and the forward plans for probabilistic design analysis in the detailed design and development phases.
The Vestibular Functions Research (VFR) Experiment was established to investigate the neurosensory and related physiological processes believed to be associated with the space flight nausea syndrome and to develop logical means for its prediction, prevention and treatment. The VFR Project consists of ground and spaceflight experimentation using frogs as specimens. The phase B Preliminary Design Study provided for the preliminary design of the experiment hardware, preparation of performance and hardware specification and a Phase C/D development plan, establishment of STS (Space Transportation System) interfaces and mission operations, and the study of a variety of hardware, experiment and mission options. The study consist of three major tasks: (1) mission mode trade-off; (2) conceptual design; and (3) preliminary design.
This paper describes the methodology and value of modifying allocations to reliability and maintainability requirements for the NASA Ground Systems Development and Operations (GSDO) program’s subsystems. As systems progressed through their design life cycle and hardware data became available, it became necessary to reexamine the previously derived allocations. This iterative process provided an opportunity for the reliability engineering team to reevaluate allocations as systems moved beyond their conceptual and preliminary design phases. These new allocations are based on updated designs and maintainability characteristics of the components. It was found that trade-offs in reliability and maintainability were essential to ensuring the integrity of the reliability and maintainability analysis. This paper discusses the results of reliability and maintainability reallocations made for the GSDO subsystems as the program nears the end of its design phase.
This paper describes the methodology and value of modifying allocations to reliability and maintainability requirements for the NASA Ground Systems Development and Operations (GSDO) programs subsystems. As systems progressed through their design life cycle and hardware data became available, it became necessary to reexamine the previously derived allocations. This iterative process provided an opportunity for the reliability engineering team to reevaluate allocations as systems moved beyond their conceptual and preliminary design phases. These new allocations are based on updated designs and maintainability characteristics of the components. It was found that trade-offs in reliability and maintainability were essential to ensuring the integrity of the reliability and maintainability analysis. This paper discusses the results of reliability and maintainability reallocations made for the GSDO subsystems as the program nears the end of its design phase.
The research focus of this project is to assist in the closure of Measurement, Monitoring and Control System (MMCS) and other electrical requirements in support of the B2 Space Launch System (SLS) Core Stage Green Run Test Project. Alongside this goal I am to understand project management tools to analyze and control activities/tasks associated with those items. The project I am working on will assist electrical engineers in developing and or identifying closure rationale for the MMCS and electrical requirements. Also as serving the role of a training project manager, I am to develop and maintain a method for tracking progress with estimate completion dates specifically identifying those items during this performance window. The methods I used in order to perform the research consisted of worddocuments, excel sheets, and pdf documents needed for review. For example, documents consisted of: a SLS Core Stage Green Run Facility Requirement Document (FRD) identifying the SSC MMCS and electrical requirements, a Stage Controller to SSC Interface Control Document (ICD) identifying the SSC requirements, and the B2 SLS Core Stage Green Run Test project System Requirements Document (SRD) which identifies the MMCS and electrical requirements. The files were sent to me by both mentors, Mr. Barry Robinson and Ms. Dawn Davis. Overall, the review process for the word documents and excel spreadsheets proved to be successful. The data for the electrical components were accurate and were consistent with the original recorded data. However, the consistency with the pdf documents did not follow up all the way. Attention to this mistake was made and further revisions were done in order for the data to agree with each other. Furthermore, an itinerary was designed using Microsoft Outlook in order to track progress with estimated completion dates. This project contributes to NASA/Center Missions and Goals through the Waterfall Model. The Waterfall Model is a linear system used for engineering design. In the Waterfall Model, the fourth step is Verification and Validation. This involves installation, testing, and debugging of the B2 SLS Core Stage electrical components. For the SLS Core Stage Green Run Test Project, each requirement contained in this approved requirements set will have at least one Verification Item (VI) assigned to it. During the design phase, VIs will mostly consist of Analysis or Inspection types. Design phase VIs and closure information will be documented in Dynamics Data Management System (DDMS) in the form of analysis reports and design documentation.
The National Aeronautics and Space Administration (NASA) is embarking on a course to expand human presence beyond Low Earth Orbit (LEO) while expanding its mission to explore the solar system. Destinations such as Near Earth Asteroids (NEA), Mars and its moons, and the outer planets are but a few of the mission targets. NASA has established numerous offices specializing in specific space environments disciplines that will serve to enable these missions. To complement these existing discipline offices, a concept focusing on the development of space environment and effects application is presented. This includes space climate, space weather, and natural and induced space environments. This space environment and effects application is composed of 4 topic areas; characterization and modeling, engineering effects, prediction and operation, and mitigation and avoidance. These topic areas are briefly described below. Characterization and modeling of space environments will primarily focus on utilization during Program mission concept, planning, and design phases. Engineering effects includes materials testing and flight experiments producing data to be used in mission planning and design phases. Prediction and operation pulls data from existing sources into decision-making tools and empirical data sets to be used during the operational phase of a mission. Mitigation and avoidance will develop techniques and strategies used in the design and operations phases of the mission. The goal of this space environment and effects application is to develop decision-making tools and engineering products to support the mission phases of mission concept through operations by focusing on transitioning research to operations. Products generated by this space environments and effects application are suitable for use in anomaly investigations. This paper will outline the four topic areas, describe the need, and discuss an organizational structure for this space environments and effects application.
The role of computational fluid dynamics (CFD) programs is usually one of analysis. Generally they are not used in the design phase of a project. There was an effort to integrate CFD codes into the design phase of combustion devices, specifically, in the design of the Space Transportation Main Engine (STME) nozzle. Before the results of such analyses can be accepted, the credibility of the CFD codes upon which they are based must be established. The effort to assess the capability of the NASA code FDNS2D to compute the heat transfer to a solid bounding surface is detailed. Specifically, high speed flow over a flat plate is considered, and the resulting wall shear stress, and heat transfer are computed. These values are compared against analytical results (for wall shear stress) and experimental data (for heat transfer). A brief description is given of the FDNS2D code, with special emphasis on how it handles solid wall boundary conditions. The flow conditions and the FDNS solution are presented, along with comparison to analytical and experimental data. Some intermediate observations are then made, followed by a recommendation for adoption of an alternate method for computing the wall heat flux.
The United States National Aeronautics and Space Administration (NASA) is in the midst of an effort to design and build a safe and affordable heavy lift vehicle to go to the moon and beyond. To achieve that, NASA is seeking more innovative and efficient approaches to reduce cost while maintaining an acceptable level of safety and mission success. One area that has the potential to contribute significantly to achieving NASA safety and affordability goals is Reliability and Maintainability (R&M) engineering. Inadequate reliability or failure of critical safety items may directly jeopardize the safety of the user(s) and result in a loss of life. Inadequate reliability of equipment may directly jeopardize mission success. Systems designed to be more reliable (fewer failures) and maintainable (fewer resources needed) can lower the total life cycle cost. The Department of Defense (DOD) and industry experience has shown that optimized and adequate levels of R&M are critical for achieving a high level of safety and mission success, and low sustainment cost. Also, lessons learned from the Space Shuttle program clearly demonstrated the importance of R&M engineering in designing and operating safe and affordable launch systems. The Challenger and Columbia accidents are examples of the severe impact of design unreliability and process induced failures on system safety and mission success. These accidents demonstrated the criticality of reliability engineering in understanding component failure mechanisms and integrated system failures across the system elements interfaces. Experience from the shuttle program also shows that insufficient Reliability, Maintainability, and Supportability (RMS) engineering analyses upfront in the design phase can significantly increase the sustainment cost and, thereby, the total life cycle cost. Emphasis on RMS during the design phase is critical for identifying the design features and characteristics needed for time efficient processing, improved operational availability, and optimized maintenance and logistic support infrastructure. This paper discusses the role of R&M in a program acquisition phase and the potential impact of R&M on safety, mission success, operational availability, and affordability. This includes discussion of the R&M elements that need to be addressed and the R&M analyses that need to be performed in order to support a safe and affordable system design. The paper also provides some lessons learned from the Space Shuttle program on the impact of R&M on safety and affordability.
The Magnetospheric Multiscale Mission (MMS) is a NASA mission intended to make fundamental advancements in our understanding of the Earth's Magnetosphere. There are three processes that MMS will study including magnetic reconnection, charged particle acceleration, and turbulence. There are four phases in the nominal mission and this work addresses some of the outstanding issues in phase I. The nominal phase I orbit is 1.2 x 12 R(sub e) highly elliptic orbit with four spacecraft nominally forming a regular tetrahedron. In this paper we investigate the relative dynamics of the four MMS spacecraft about an assumed reference orbit. There are several tetrahedron dimensions required in Phase I of the mission and in this work we design optimal tetrahedrons for the 10 km baseline. The performance metric used in the optimization process is directly related to the science return, and is based on an extension of previous work performed by Glassmeier. The optimizer we use is a commercially available Sequential Quadratic Programming (SQP) routine. Multiple optimal solutions are found, and we characterize how the performance of the formation varies between different regions of the reference orbit.
As system designs become more complex, determining the best locations to add sensors and test points for the purpose of testing and monitoring these designs becomes more difficult. Not only must the designer take into consideration all real and potential faults of the system, he or she must also find efficient ways of detecting and isolating those faults. Because sensors and cabling take up valuable space and weight on a system, and given constraints on bandwidth and power, it is even more difficult to add sensors into these complex designs after the design has been completed. As a result, a number of software tools have been developed to assist the system designer in proper placement of these sensors during the system design phase of a project. One of the key functions provided by many of these software programs is a testability analysis of the system essentially an evaluation of how observable the system behavior is using available tests. During the design phase, testability metrics can help guide the designer in improving the inherent testability of the design. This may include adding, removing, or modifying tests; breaking up feedback loops, or changing the system to reduce fault propagation. Given a set of test requirements, the analysis can also help to verify that the system will meet those requirements. Of course, a testability analysis requires that a software model of the physical system is available. For the analysis to be most effective in guiding system design, this model should ideally be constructed in parallel with these efforts. The purpose of this paper is to present the final testability results of the Advanced Diagnostic and Prognostic Testbed (ADAPT) after the system model was completed. The tool chosen to build the model and to perform the testability analysis with is the Testability Engineering and Maintenance System Designer (TEAMS-Designer). The TEAMS toolset is intended to be a solution to span all phases of the system, from design and development through health management and maintenance. TEAMS-Designer is the model-building and testability analysis software in that suite.
The high temperature performance of solid lubricated rolling elements was conducted with a specially designed traction (friction) test apparatus. Graphite lubricants containing three additives (silver, phosphate glass, and zinc orthophosphate) were evaluated from room temperature to 540 C. Two hard coats were also evaluated. The evaluation of these lubricants, using a burnishing method of application, shows a reasonable transfer of lubricant and wear protection for short duration testing except in the 200 C temperature range. The graphite lubricants containing silver and zinc orthophosphate additives were more effective than the phosphate glass material over the test conditions examined. Traction coefficients ranged from a low of 0.07 to a high of 0.6. By curve fitting the traction data, empirical equations for slope and maximum traction coefficient as a function of contact pressure (P), rolling speed (U), and temperature (T) can be developed for each lubricant. A solid lubricant traction model was incorporated into an advanced bearing analysis code (SHABERTH). For comparison purposes, preliminary heat generation calculations were made for both oil and solid lubricated bearing operation. A preliminary analysis indicated a significantly higher heat generation for a solid lubricated ball bearing in a deep groove configuration. An analysis of a cylindrical roller bearing configuration showed a potential for a low friction solid lubricated bearing.
A study which consisted of a series of design analyses for an Attitude Control System (ACS) to be incorporated into the Re-usable Re-entry Satellite (RRS) was performed. The main thrust of the study was associated with defining the control laws and estimating the mass and power requirements of the ACS needed to meet the specified performance goals. The analyses concentrated on the different on-orbit control modes which start immediately after the separation of the RRS from the launch vehicle. The three distinct on-orbit modes considered for these analyses are as follows: (1) Mode 1 - A Gravity Gradient (GG) three-axis stabilized spacecraft with active magnetic control; (2) Mode 2 - A GG stabilized mode with a controlled yaw rotation rate ('rotisserie') using three-axis magnetic control and also incorporating a 10 N-m-s momentum wheel along the (Z) yaw axis; and (3) Mode 3 - A spin stabilized mode of operation with the spin about the pitch (Y) axis, incorporating a 20 N-m-s momentum wheel along the pitch (Y) axis and attitude control via thrusters. To investigate the capabilities of the different controllers in these various operational modes, a series of computer simulations and trade-off analyses have been made to evaluate the achievable performance levels, and the necessary mass and power requirements.
Significant progress has been made toward all of the goals for the first phase of the project short of actual fabrication of a light path. Two alternative approaches to fabricating gold mirrors using the basic LIGA process were developed, one using electroplated solid gold mirrors and the second using gold plated over a nickel base. A new method of fabrication, the transfer mask process, was developed and demonstrated. Analysis of the projected surface roughness and beam divergence effects was completed. With gold surface with low surface roughness scattering losses are expected to be insignificant. Beam divergence due to diffraction will require a modification of the original design, but should be eliminated by fabricating mirrors 1000 mu m in height by 1000 mu m in width and using a source with an initial beam radius greater than 300 mu m. This may eliminate any need for focusing optics. Since the modified design does not affect the mask layout, ordering of the mask and fabrication of the test structures can begin immediately at the start of Phase 1.
Empirical sizing guidelines such as tail volume coefficients have long been used in the early aircraft design phases for sizing stabilizers, resulting in conservatively stable aircraft. While successful, this results in increased empty weight, reduced performance, and greater procurement and operational cost relative to an aircraft with optimally sized surfaces. Including flight dynamics in the conceptual design process allows the design to move away from empirical methods while implementing modern control techniques. A challenge of flight dynamics and control is the numerous design variables, which are changing fluidly throughout the conceptual design process, required to evaluate the system response to some disturbance. This research focuses on addressing that challenge not by implementing higher order tools, such as computational fluid dynamics, but instead by linking the lower order tools typically used within the conceptual design process so each discipline feeds into the other. In thisresearch, flight dynamics and control was incorporated into the conceptual design process along with the traditional disciplines of vehicle sizing, weight estimation, aerodynamics, and performance. For the controller, a linear quadratic regulator structure with constant gains has been specified to reduce the user input. Coupling all the disciplines in the conceptual design phase allows the aircraft designer to explore larger design spaces where stabilizers are sized according to dynamic response constraints rather than historical static margin and volume coefficient guidelines.
This report summarizes the Truss Braced Wing (TBW) work accomplished by the Boeing Subsonic Ultra Green Aircraft Research (SUGAR) team, consisting of Boeing Research and Technology, Boeing Commercial Airplanes, General Electric, Georgia Tech, Virginia Tech, NextGen Aeronautics, and Microcraft. A multi-disciplinary optimization (MDO) environment defined the geometry that was further refined for the updated SUGAR High TBW configuration. Airfoil shapes were tested in the NASA TCT facility, and an aeroelastic model was tested in the NASA TDT facility. Flutter suppression was successfully demonstrated using control laws derived from test system ID data and analysis models. Aeroelastic impacts for the TBW design are manageable and smaller than assumed in Phase I. Flutter analysis of TBW designs need to include pre-load and large displacement non-linear effects to obtain a reasonable match to test data. With the updated performance and sizing, fuel burn and energy use is reduced by 54% compared to the SUGAR Free current technology Baseline (Goal 60%). Use of the unducted fan version of the engine reduces fuel burn and energy by 56% compared to the Baseline. Technology development roadmaps were updated, and an airport compatibility analysis established feasibility of a folding wing aircraft at existing airports.
The ribbon-cabling system used for the AEGIS phased array which provides minimum cable bulk, complete EMI shielding, rugged mechanical design, repeatable electrical characteristics, and ease of assembly and maintenance is described. The ribbon cables are 0.040-inch thick, and in widths up to 2 1/2 inches. Their terminations are molded connectors that can be grouped in a three-tier arrangement, with cable branching accomplished by a matrix-welding technique.