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Life-span knowledge engineering for space operations

Ordinarily, knowledge engineering is thought of as the process of translating the knowledge and problem solving strategies of a human expert into rules and procedures incorporated into a machine based expert system which can, given adequate input, solve the same sorts of problems as the expert. One appeal of these knowledge based systems is their ability to take care of problems without having a human expert present. For work in space, being independent of humans is especially important both for situations where devices will be in remote or dangerous locales and for situations such as space stations where human resources are limited and schedules are tight. In qualification of the above ideas, it is argued herein that the notion of knowledge engineering and the expectations for its application should be extended beyond the period of construction of unit expert systems to the entire knowledge system management associated with one or another real systems, whether it is a piece of hardware or an entire human-machine operation such as a lunar factory.

Hays, Dan↗

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. During the ABEDRR effort, the Dynetics Team has modified flight-proven Apollo-Saturn F-1 engine components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically-produced engine that could potentially both replace the RD-180 on Atlas V and satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete fabrication and assembly soon and continue testing through late 2019. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements..

Crocker, Andrew M.↗

Powder metallurgy bearings for advanced rocket engines

Traditional ingot metallurgy was pushed to the limit for many demanding applications including antifriction bearings. New systems require corrosion resistance, better fatigue resistance, and higher toughness. With conventional processing, increasing the alloying level to achieve corrosion resistance results in a decrease in other properties such as toughness. Advanced powder metallurgy affords a viable solution to this problem. During powder manufacture, the individual particle solidifies very rapidly; as a consequence, the primary carbides are very small and uniformly distributed. When properly consolidated, this uniform structure is preserved while generating a fully dense product. Element tests including rolling contact fatigue, hot hardness, wear, fracture toughness, and corrosion resistance are underway on eleven candidate P/M bearing alloys and results are compared with those for wrought 440C steel, the current SSME bearing material. Several materials which offer the promise of a significant improvement in performance were identified.

Fleck, J. N.↗

Mean Flow Augmented Acoustics in Rocket Systems

Oscillatory motion in solid rocket motors and liquid engines has long been a subject of concern. Many rockets display violent fluctuations in pressure, velocity, and temperature originating from the complex interactions between the combustion process and gas dynamics. The customary approach to modeling acoustic waves inside a rocket chamber is to apply the classical inhomogeneous wave equation to the combustion gas. The assumption of a linear, non-dissipative wave in a quiescent fluid remains valid while the acoustic amplitudes are small and local gas velocities stay below Mach 0.2. The converging section of a rocket nozzle, where gradients in pressure, density, and velocity become large, is a notable region where this approach is not applicable. The expulsion of unsteady energy through the nozzle of a rocket is identified as the predominate source of acoustic damping for most rocket systems. An accurate model of the acoustic behavior within this region where acoustic modes are influenced by the presence of a steady mean flow is required for reliable stability predictions. Recently, an approach to address nozzle damping with mean flow effects was implemented by French [1]. This new approach extends the work originated by Sigman and Zinn [2] by solving the acoustic velocity potential equation (AVPE) formulated by perturbing the Euler equations [3]. The acoustic velocity potential (psi) describing the acoustic wave motion in the presence of an inhomogeneous steady high-speed flow is defined by, (del squared)(psi) − (lambda/c)(exp 2)(psi) − M(dot)[M(dot)(del)(del(psi))] − 2(lambda(M/c) + (M(dot)del(M))(dot)del(psi)−2(lambda)(psi)[M(dot)del(1/c)]=0 (1) with M as the Mach vector, c as the speed of sound, and lambda as the complex eigenvalue. French apply the finite volume method to solve the steady flow field within the combustion chamber and nozzle with inviscid walls. The complex eigenvalues and eigenvector are determined with the use of the ARPACK eigensolver. The present study employs the COMSOL Multphysics framework to solve the coupled eigenvalue problem using the finite element approach. The study requires one way coupling of the CFD High Mach Number Flow (HMNF) and mathematics module. The HMNF module evaluated the gas flow inside of a solid rocket motor using St. Robert's law modeling solid propellant burn rate, slip boundary conditions, and the supersonic outflow condition. Results from the HMNF model are used by the coefficient form of the mathematics module to determine the eigenvalues of the AVPE. The mathematics model is truncated at the nozzle sonic line, where a zero flux boundary condition is self-satisfying. The remaining boundaries are modeled with a zero flux boundary condition, assuming zero acoustic absorption on all surfaces. Pertinent results from these analyses are the complex valued eigenvalue and eigenvectors. Comparisons are made to the French results to evaluate the modeling approach. A comparison of the French results with that of the present analysis is displayed in figures 1 and 2, respectively. The graphic shows the first tangential eigenvector's real (a) and imaginary (b) values.

Fischbach, Sean R.↗

Integration of the Remote Agent for the NASA Deep Space One Autonomy Experiment

This paper describes the integration of the Remote Agent (RA), a spacecraft autonomy system which is scheduled to control the Deep Space 1 spacecraft during a flight experiment in 1999. The RA is a reusable, model-based autonomy system that is quite different from software typically used to control an aerospace system. We describe the integration challenges we faced, how we addressed them, and the lessons learned. We focus on those aspects of integrating the RA that were either easier or more difficult than integrating a more traditional large software application because the RA is a model-based autonomous system. A number of characteristics of the RA made integration process easier. One example is the model-based nature of RA. Since the RA is model-based, most of its behavior is not hard coded into procedural program code. Instead, engineers specify high level models of the spacecraft's components from which the Remote Agent automatically derives correct system-wide behavior on the fly. This high level, modular, and declarative software description allowed some interfaces between RA components and between RA and the flight software to be automatically generated and tested for completeness against the Remote Agent's models. In addition, the Remote Agent's model-based diagnosis system automatically diagnoses when the RA models are not consistent with the behavior of the spacecraft. In flight, this feature is used to diagnose failures in the spacecraft hardware. During integration, it proved valuable in finding problems in the spacecraft simulator or flight software. In addition, when modifications are made to the spacecraft hardware or flight software, the RA models are easily changed because they only capture a description of the spacecraft. one does not have to maintain procedural code that implements the correct behavior for every expected situation. On the other hand, several features of the RA made it more difficult to integrate than typical flight software. For example, the definition of correct behavior is more difficult to specify for a system that is expected to reason about and flexibly react to its environment than for a traditional flight software system. Consequently, whenever a change is made to the RA it is more time consuming to determine if the resulting behavior is correct. We conclude the paper with a discussion of future work on the Remote Agent as well as recommendations to ease integration of similar autonomy projects.

Dorais, Gregory A.↗

Basin-Scale Assessment of the Land Surface Water Budget in the National Centers for Environmental Prediction Operational and Research NLDAS-2 Systems

The purpose of this study is to evaluate the components of the land surface water budget in the four land surface models (Noah, SAC-Sacramento Soil Moisture Accounting Model, (VIC) Variable Infiltration Capacity Model, and Mosaic) applied in the newly implemented National Centers for Environmental Prediction (NCEP) operational and research versions of the North American Land Data Assimilation System version 2 (NLDAS-2). This work focuses on monthly and annual components of the water budget over 12 National Weather Service (NWS) River Forecast Centers (RFCs). Monthly gridded FLUX Network (FLUXNET) evapotranspiration (ET) from the Max-Planck Institute (MPI) of Germany, U.S. Geological Survey (USGS) total runoff (Q), changes in total water storage (dS/dt, derived as a residual by utilizing MPI ET and USGS Q in the water balance equation), and Gravity Recovery and Climate Experiment (GRACE) observed total water storage anomaly (TWSA) and change (TWSC) are used as reference data sets. Compared to these ET and Q benchmarks, Mosaic and SAC (Noah and VIC) in the operational NLDAS-2 overestimate (underestimate) mean annual reference ET and underestimate (overestimate) mean annual reference Q. The multimodel ensemble mean (MME) is closer to the mean annual reference ET and Q. An anomaly correlation (AC) analysis shows good AC values for simulated monthly mean Q and dS/dt but significantly smaller AC values for simulated ET. Upgraded versions of the models utilized in the research side of NLDAS-2 yield largely improved performance in the simulation of these mean annual and monthly water component diagnostics. These results demonstrate that the three intertwined efforts of improving (1) the scientific understanding of parameterization of land surface processes, (2) the spatial and temporal extent of systematic validation of land surface processes, and (3) the engineering-oriented aspects such as parameter calibration and optimization are key to substantially improving product quality in various land data assimilation systems.

NLDAS-2↗

How the INCOSE Model-Based Capability Matrix Has Steered Model-Based Systems Engineering Transformation at NASA

The National Aeronautics and Space Administration (NASA) is embarking on new, complex, and diverse missions to accomplish its scientific and exploration objectives, and it views digital transformation as a key enabler for those missions. The NASA Model-Based Systems Engineering (MBSE) Lead-ership Team (MLT) is leading the charge in the digital transformation of the systems engineering domain at NASA, and it is using the INCOSE Model-Based Capability Matrix (MBCM) as a roadmap. This paper discusses the modifications and tailoring of the INCOSE MBCM (Hale & Hoheb, 2020) for use at NASA, the process the team has taken on multiple rounds of assessment, findings to date, and work products that have been generated as a result of the assessment. The paper will also discuss findings and potential changes that should be made to the original product.

MBSE↗

Automated Power Assessment for Helicopter Turboshaft Engines

An accurate indication of available power is required for helicopter mission planning purposes. Available power is currently estimated on U.S. Army Blackhawk helicopters by performing a Maximum Power Check (MPC), a manual procedure performed by maintenance pilots on a periodic basis. The MPC establishes Engine Torque Factor (ETF), an indication of available power. It is desirable to replace the current manual MPC procedure with an automated approach that will enable continuous real-time assessment of available power utilizing normal mission data. This report presents an automated power assessment approach which processes data currently collected within helicopter Health and Usage Monitoring System (HUMS) units. The overall approach consists of: 1) a steady-state data filter which identifies and extracts steady-state operating points within HUMS data sets; 2) engine performance curve trend monitoring and updating; and 3) automated ETF calculation. The algorithm is coded in MATLAB (The MathWorks, Inc.) and currently runs on a PC. Results from the application of this technique to HUMS mission data collected from UH-60L aircraft equipped with T700-GE-701C engines are presented and compared to manually calculated ETF values. Potential future enhancements are discussed.

Simon, Donald L.↗

Building Operations Efficiencies into NASA's Ares I Crew Launch Vehicle Design

The U.S. Vision for Space Exploration guides the National Aeronautics and Space Administration's (NASA's) challenging missions that expand humanity's boundaries and open new routes to the space frontier. With the Agency's commitment to complete the International Space Station (ISS) and to retire the venerable Space Shuttle by 2010, the NASA Administrator commissioned the Exploration Systems Architecture Study (ESAS) in 2005 to analyze options for safe, simple, cost-efficient launch solutions that could deliver human-rated space transportation capabilities in a timely manner within fixed budget guidelines. The Exploration Launch Projects (ELP) Office, chartered by the Constellation Program in October 2005, has been conducting systems engineering studies and business planning to successively refine the design configurations and better align vehicle concepts with customer and stakeholder requirements, such as significantly reduced life-cycle costs. As the Agency begins the process of replacing the Shuttle with a new generation of spacecraft destined for missions beyond low-Earth orbit to the Moon and Mars, NASA is designing the follow-on crew and cargo launch systems for maximum operational efficiencies. To sustain the long-term exploration of space, it is imperative to reduce the $4 billion NASA typically spends on space transportation each year. This paper gives toplevel information about how the follow-on Ares I Crew Launch Vehicle (CLV) is being designed for improved safety and reliability, coupled with reduced operations costs. These methods include carefully developing operational requirements; conducting operability design and analysis; using the latest information technology tools to design and simulate the vehicle; and developing a learning culture across the workforce to ensure a smooth transition between Space Shuttle operations and Ares vehicle development.

Dumbacher, Daniel L.↗

Getting a Cohesive Answer from a Common Start: Scalable Multidisciplinary Analysis through Transformation of a System Model

One of the challenges of systems engineering is in working multidisciplinary problems in a cohesive manner. When planning analysis of these problems, system engineers must tradeoff time and cost for analysis quality and quantity. The quality is associated with the fidelity of the multidisciplinary models and the quantity is associated with the design space that can be analyzed. The tradeoff is due to the resource intensive process of creating a cohesive multidisciplinary system model and analysis. Furthermore, reuse or extension of the models used in one stage of a product life cycle for another is a major challenge. Recent developments have enabled a much less resource-intensive and more rigorous approach than handwritten translation scripts or codes of multidisciplinary models and their analyses. The key is to work from a core system model defined in a MOF-based language such as SysML and in leveraging the emerging tool ecosystem, such as Query-View- Transform (QVT), from the OMG community. SysML was designed to model multidisciplinary systems and analyses. The QVT standard was designed to transform SysML models. The Europa Hability Mission (EHM) team has begun to exploit these capabilities. In one case, a Matlab/Simulink model is generated on the fly from a system description for power analysis written in SysML. In a more general case, a symbolic mathematical framework (supported by Wolfram Mathematica) is coordinated by data objects transformed from the system model, enabling extremely flexible and powerful tradespace exploration and analytical investigations of expected system performance.

Cole, Bjorn↗

Numerical Propulsion System Simulation (NPSS): An Award Winning Propulsion System Simulation Tool

The Numerical Propulsion System Simulation (NPSS) is a full propulsion system simulation tool used by aerospace engineers to predict and analyze the aerothermodynamic behavior of commercial jet aircraft, military applications, and space transportation. The NPSS framework was developed to support aerospace, but other applications are already leveraging the initial capabilities, such as aviation safety, ground-based power, and alternative energy conversion devices such as fuel cells. By using the framework and developing the necessary components, future applications that NPSS could support include nuclear power, water treatment, biomedicine, chemical processing, and marine propulsion. NPSS will dramatically reduce the time, effort, and expense necessary to design and test jet engines. It accomplishes that by generating sophisticated computer simulations of an aerospace object or system, thus enabling engineers to "test" various design options without having to conduct costly, time-consuming real-life tests. The ultimate goal of NPSS is to create a numerical "test cell" that enables engineers to create complete engine simulations overnight on cost-effective computing platforms. Using NPSS, engine designers will be able to analyze different parts of the engine simultaneously, perform different types of analysis simultaneously (e.g., aerodynamic and structural), and perform analysis in a more efficient and less costly manner. NPSS will cut the development time of a new engine in half, from 10 years to 5 years. And NPSS will have a similar effect on the cost of development: new jet engines will cost about a billion dollars to develop rather than two billion. NPSS is also being applied to the development of space transportation technologies, and it is expected that similar efficiencies and cost savings will result. Advancements of NPSS in fiscal year 2001 included enhancing the NPSS Developer's Kit to easily integrate external components of varying fidelities, providing the initial Visual-Based Syntax (VBS) capability, and developing additional capabilities to support space transportation. NPSS was supported under NASA's High Performance Computing and Communications Program. Through the NASA/Industry Cooperative Effort agreement, NASA Glenn and its industry and Government partners are developing NPSS. The NPSS team consists of propulsion experts and software engineers from GE Aircraft Engines, Pratt & Whitney, The Boeing Company, Honeywell, Rolls-Royce Corporation, Williams International, Teledyne Continental Motors, Arnold Engineering Development Center, Wright Patterson Air Force Base, and the NASA Glenn Research Center. Glenn is leading the way in developing NPSS--a method for solving complex design problems that's faster, better, and cheaper.

Stauber, Laurel J.↗

Advanced High Temperature Polymer Matrix Composites for Gas Turbine Engines Program Expansion

This document, submitted by AlliedSignal Engines (AE), a division of AlliedSignal Aerospace Company, presents the program final report for the Advanced High Temperature Polymer Matrix Composites for Gas Turbine Engines Program Expansion in compliance with data requirements in the statement of work, Contract No. NAS3-97003. This document includes: 1 -Technical Summary: a) Component Design, b) Manufacturing Process Selection, c) Vendor Selection, and d) Testing Validation: 2-Program Conclusion and Perspective. Also, see the Appendix at the back of this report. This report covers the program accomplishments from December 1, 1996, to August 24, 1998. The Advanced High Temperature PMC's for Gas Turbine Engines Program Expansion was a one year long, five task technical effort aimed at designing, fabricating and testing a turbine engine component using NASA's high temperature resin system AMB-21. The fiber material chosen was graphite T650-35, 3K, 8HS with UC-309 sizing. The first four tasks included component design and manufacturing, process selection, vendor selection, component fabrication and validation testing. The final task involved monthly financial and technical reports.

Hanley, David↗

Ultrasonic Polishing

The ultrasonic polishing process makes use of the high-frequency (ultrasonic) vibrations of an abradable tool which automatically conforms to the work piece and an abrasive slurry to finish surfaces and edges on complex, highly detailed, close tolerance cavities in materials from beryllium copper to carbide. Applications range from critical deburring of guidance system components to removing EDM recast layers from aircraft engine components to polishing molds for forming carbide cutting tool inserts or injection molding plastics. A variety of materials including tool steels, carbides, and even ceramics can be successfully processed. Since the abradable tool automatically conforms to the work piece geometry, the ultrasonic finishing method described offers a number of important benefits in finishing components with complex geometries.

Gilmore, Randy↗

A PPE Use Case on Configuration Management Approach for MBSE

Systems engineers worldwide have been working to implement Model-based Systems Engineering (MBSE) environments, tools, and methodologies. MBSE is a formalized application of modeling to support systems engineering, including requirements, design, analysis, verification, and validation activities over the project’s lifecycle[1]; MBSE captures the system data into a digital environment. Significant benefits of MBSE includes a reduction in the time in performing systems engineering activities and an improvement higher fidelity data production. As more Systems Engineers are using MBSE, the models it produces are becoming the source of truth for Systems Engineering artifacts. As we move towards using these models as the source of truth, a more rigorous Configuration Management (CM) infrastructure is needed. Many of the MBSE tools provide CM options but utilizing them efficiently and effectively can be challenging. More rigorous methods and tools are needed to assist with keeping track of changes in the model, making sure inadvertent changes to baseline data did not occur, visibility of changes in the different model versions, and the impacts of changes to the models. System engineers and configuration management personnel from the Power and Propulsion Element (PPE) project at NASA Glenn Research Center have been working to develop a modeling construct that allows models to be the source of truth and maintain a configuration managed baseline. This paper presents a process that leverages the existing CM tools and describes how PPE used this process to manage changes more rigorously. It will describe the process behind building the model architecture that utilizes the MBSE tool capabilities and the configuration management process. It will contain some of the advantages and disadvantages of the architecture that the PPE project had settled upon utilizing, as well as some enhanced capabilities that the PPE MBSE team has developed.

MBSE↗

The liquid hydrogen option for the subsonic transport - A status report

Studies dealing with the use of liquid hydrogen for fuel in subsonic air transport systems are reviewed. Topics of the studies include the possibility for economical production of hydrogen, the problems associated with the efficient liquefaction of the gas, the development of insulation materials and materials for long-lasting liquid hydrogen fuel tanks, the difficulties related to fueling processes and the installation of liquid hydrogen fuel stations at major air terminals, an assessment of the hazards connected with liquid hydrogen fuels, and the engineering and design problems involved in incorporating liquid hydrogen fuel systems into large subsonic passenger aircraft.

Korycinski, P. F.↗

Achieving Space Shuttle Abort-to-Orbit Using the Five-Segment Booster

The Five-Segment Booster design concept was evaluated by a team that determined the concept to be feasible and capable of achieving the desired abort-to-orbit capability when used in conjunction with increased Space Shuttle main engine throttle capability. The team (NASA Johnson Space Center, NASA Marshall Space Flight Center, ATK Thiokol Propulsion, United Space Alliance, Lockheed-Martin Space Systems, and Boeing) selected the concept that provided abort-to-orbit capability while: 1) minimizing Shuttle system impacts by maintaining the current interface requirements with the orbiter, external tank, and ground operation systems; 2) minimizing changes to the flight-proven design, materials, and processes of the current four-segment Shuttle booster; 3) maximizing use of existing booster hardware; and 4) taking advantage of demonstrated Shuttle main engine throttle capability. The added capability can also provide Shuttle mission planning flexibility. Additional performance could be used to: enable implementation of more desirable Shuttle safety improvements like crew escape, while maintaining current payload capability; compensate for off nominal performance in no-fail missions; and support missions to high altitudes and inclinations. This concept is a low-cost, low-risk approach to meeting Shuttle safety upgrade objectives. The Five-Segment Booster also has the potential to support future heavy-lift missions.

Craft, Joe↗

A unified approach to computer analysis and modeling of spacecraft environmental interactions

A new, coordinated, unified approach to the development of spacecraft plasma interaction models is proposed. The objective is to eliminate the unnecessary duplicative work in order to allow researchers to concentrate on the scientific aspects. By streamlining the developmental process, the interchange between theories and experimentalists is enhanced, and the transfer of technology to the spacecraft engineering community is faster. This approach is called the UNIfied Spacecraft Interaction Model (UNISIM). UNISIM is a coordinated system of software, hardware, and specifications. It is a tool for modeling and analyzing spacecraft interactions. It will be used to design experiments, to interpret results of experiments, and to aid in future spacecraft design. It breaks a Spacecraft Ineraction analysis into several modules. Each module will perform an analysis for some physical process, using phenomenology and algorithms which are well documented and have been subject to review. This system and its characteristics are discussed.

Katz, I.↗

The Joint Polar Satellite System (JPSS) Program's Algorithm Change Process (ACP): Past, Present and Future

The Joint Polar Satellite System (JPSS) Program Office is the supporting organization for the Suomi National Polar Orbiting Partnership (S-NPP) and JPSS-1 satellites. S-NPP carries the following sensors: VIIRS, CrIS, ATMS, OMPS, and CERES with instruments that ultimately produce over 25 data products that cover the Earths weather, oceans, and atmosphere. A team of scientists and engineers from all over the United States document, monitor and fix errors in operational software code or documentation with the algorithm change process (ACP) to ensure the success of the S-NPP and JPSS 1 missions by maintaining quality and accuracy of the data products the scientific community relies on. This poster will outline the programs algorithm change process (ACP), identify the various users and scientific applications of our operational data products and highlight changes that have been made to the ACP to accommodate operating system upgrades to the JPSS programs Interface Data Processing Segment (IDPS), so that the program is ready for the transition to the 2017 JPSS-1 satellite mission and beyond.

Joint Polar Satellite System↗