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System safety in Stirling engine development

The DOE/NASA Stirling Engine Project Office has required that contractors make safety considerations an integral part of all phases of the Stirling engine development program. As an integral part of each engine design subtask, analyses are evolved to determine possible modes of failure. The accepted system safety analysis techniques (Fault Tree, FMEA, Hazards Analysis, etc.) are applied in various degrees of extent at the system, subsystem and component levels. The primary objectives are to identify critical failure areas, to enable removal of susceptibility to such failures or their effects from the system and to minimize risk.

Bankaitis, H.↗

Report to the administrator by the NASA Aerospace Safety Advisory Panel on the Skylab program. Volume 1: Summary report

Contractor and NASA technical management for the development and manufacture of the Skylab modules is reviewed with emphasis on the following management controls: configuration and interface management; vendor control; and quality control of workmanship. A review of the modified two-stage Saturn V launch vehicle which focused on modifications to accommodate the Skylab payload; resolution of prior flight anomalies; and changes in personnel and management systems is presented along with an evaluation of the possible age-life and storage problems for the Saturn 1-B launch vehicle. The NASA program management's visibility and control of contractor operations, systems engineering and integration, the review process for the evaluation of design and flight hardware, and the planning process for mission operations are investigated. It is concluded that the technical management system for development and fabrication of the modules, spacecraft, and launch vehicles, the process of design and hardware acceptance reviews, and the risk assessment activities are satisfactory. It is indicated that checkout activity, integrated testing, and preparations for and execution of mission operation require management attention.

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The Environment for Application Software Integration and Execution (EASIE) version 1.0. Volume 1: Executive overview

The Environment for Application Software Integration and Execution (EASIE) provides a methodology and a set of software utility programs to ease the task of coordinating engineering design and analysis codes. EASIE was designed to meet the needs of conceptual design engineers that face the task of integrating many stand-alone engineering analysis programs. Using EASIE, programs are integrated through a relational database management system. Volume 1, Executive Overview, gives an overview of the functions provided by EASIE and describes their use. Three operational design systems based upon the EASIE software are briefly described.

Rowell, Lawrence F.↗

Hybrid Electric Aircraft Thermal Management: Now, New Visions and Future Concepts and Formulation

The global fuel consumption by commercial airlines has increased each year since 2009 and is predicted to reach an all-time high of 97 billion gallons in 2019. There is also an environmental impact from this: CO2 emissions from commercial passenger and freight operations totaled 918 Mt in 2018 (ICCT, 2019), or around 2.5% of global energy-related CO2 emissions. Passenger transport accounted for 81% of the total. Emissions from aviation have grown 32% over the past five years. Coupled with this aspect, there is a continuous and growing need to satisfy ever-growing electrical power needs on commercial and military aircraft. All the armed services (Army, Navy, and Air Force) are continuously trying to enhance UAV (unmanned aerial vehicle) endurance and range across a broad fleet of different aircraft. The commercial Boeing 787 requires about 1.2MWe and that is expected to grow. Current technologies used to supply increased on-board electrical power are generally: 1) “burn more fuel and convert through on-board generators” and 2) use additional heavy (i.e., weight-inefficient) and sometimes unsafe battery systems on-board the aircraft. The aircraft industry is seeking new, innovative ways to satisfy this increasing power demand. One as-yet-untapped power source is the enormous amount of “waste” thermal energy flowing out the jet engine exhaust; some estimates in smaller “by-pass” flow jet engines is several hundreds of kilowatts (e.g., Pratt & Whitney Canada PW545B turbofan). This quantity is much higher in large jet engines associated with commercial aircraft. This large waste thermal energy manifests itself in large temperature differences within the by-pass-flow engine exhaust system relative to outside ambient conditions, because of the actual by-pass engine design configuration. There is strong need to develop thermal technologies and systems that could harness and convert at least a portion of this thermal energy into useful electrical energy to satisfy growing on-board electrical needs. In addition, there is a strong desire within the aircraft and engine manufacturing community to reduce the “carbon footprint” of the industry though reduced fuel usage worldwide. NASA has a robust aircraft electrification program to meet these desires and support industry in its aircraft electrification objectives. This program is integrating thermoacoustic systems, advanced lightweight heat exchanger technology, and advanced heat pipe technology to capture and transport large amounts of engine waste thermal energy for on-board power conversion, advanced heat-pump cooling, and exergy enhancement (i.e., temperature lift). Advanced lightweight heat exchangers are envisioned to capture engine exhaust thermal energy at approximately 673 K and deliver it to efficient thermoacoustic power conversion systems operating at temperature ratios (Thot/Tcold) > 1.6. Advanced heat pipe systems are envisioned to transport thermal energy from low temperature sources, through thermoacoustic heat pumps, to high temperature needs such as wing anti-icing, fuel pre-heating, and combustion air pre-heating. The paper will discuss the current state-of-the-art, objectives, system design architecture, and remaining technical challenges in system formulation within the NASA aircraft electrification program.

Dyson, Rodger↗

2023 Artemis Crew Health and Performance System Model Development

While the NASA Human Research Program (HRP) utilizes a Crew Health and Performance (CHP) System to represent all the Agency’s efforts to ensure the health and performance of NASA astronauts, there is no shared mental model of a CHP system at NASA. Some groups may consider a CHP system to be only a medical kit, while others may not be using the concept at all. To facilitate the integration of functions and capabilities to ensure astronaut health and performance during vehicle development, HRP has proposed a CHP Shared Mental Model derived from the NASA Human Health, Medical, and Performance Spaceflight Standards (NASA-STD-3001 Vol.1/Vol.2). [1] Even though many vehicle, ground, and communication systems as well as mission operations are modeled for the Artemis Campaigns, no mission level CHP system model was created to achieve the intent of the HRP CHP Shared Mental Model. The lack of this model renders it difficult to visualize and understand how the many programs work together to provide the necessary cross program functions and capabilities to ensure the health and performance of the crew throughout an Artemis mission. For this purpose, the Exploration Medical Capability (ExMC) element of HRP developed a CHP system model for the Artemis III and IV missions to provide a view of how each program contributes to and interacts with the overall CHP system. To develop the 2023 Artemis CHP system model, ExMC leveraged existing data and models from the Moon to Mars Program Office, the Office of the Chief Health and Medical Officer (OCHMO) and the Orion, Gateway, Extravehicular Activity and Human Surface Mobility (EHP) and Human Landing System (HLS) programs. By using a Model-Based Systems Engineering (MBSE) approach, existing requirements, functions, and concepts of operations were combined to create a single system model focused on representing CHP from the launch to the return to Earth segments of the Artemis III and IV missions. Additionally, by incorporating the HRP Systems Platform for Aggregating and Relating Capabilities, or SPARC tool, the data from the programs was also related back to the 2nd volume of the NASA Human Health, Medical, and Performance Spaceflight Standard (NASA-STD-3001, Vol.2) and the human system risks identified by the Human System Risk Board (HSRB). The first version of the 2023 Artemis CHP system model was baselined in Fall of 2023 after the model was demonstrated to be a potentially useful tool for systems engineers integrating CHP capabilities in vehicle development as well as members of the Health and Medical Technical Authority providing oversight of those programs. The model may also be useful to any stakeholder of astronaut health and performance by providing insights on how an Artemis mission satisfies the NASA Human Health, Medical, and Performance Spaceflight Standards as well as how they mitigate the HSRB Human System Risks. This presentation highlights how the model was developed and the possible benefits of the model. [1] NASA HRP (2022), Crew Health and Performance System Whitepaper

Systems engineering↗

2023 Artemis Crew Health and Performance (CHP) System Model Development

While the NASA Human Research Program (HRP) utilizes a Crew Health and Performance (CHP) System to represent all the Agency’s efforts to ensure the health and performance of NASA astronauts, there is no shared mental model of a CHP system at NASA. Some groups may consider a CHP system to be only a medical kit, while others may not be using the concept at all. To facilitate the integration of functions and capabilities to ensure astronaut health and performance during vehicle development, HRP has proposed a CHP Shared Mental Model derived from the NASA Human Health, Medical, and Performance Spaceflight Standards (NASA-STD-3001 Vol.1/Vol.2). [1] Even though many vehicle, ground, and communication systems as well as mission operations are modeled for the Artemis Campaigns, no mission level CHP system model was created to achieve the intent of the HRP CHP Shared Mental Model. The lack of this model renders it difficult to visualize and understand how the many programs work together to provide the necessary cross program functions and capabilities to ensure the health and performance of the crew throughout an Artemis mission. For this purpose, the Exploration Medical Capability (ExMC) element of HRP developed a CHP system model for the Artemis III and IV missions to provide a view of how each program contributes to and interacts with the overall CHP system. To develop the 2023 Artemis CHP system model, ExMC leveraged existing data and models from the Moon to Mars Program Office, the Office of the Chief Health and Medical Officer (OCHMO) and the Orion, Gateway, Extravehicular Activity and Human Surface Mobility (EHP) and Human Landing System (HLS) programs. By using a Model-Based Systems Engineering (MBSE) approach, existing requirements, functions, and concepts of operations were combined to create a single system model focused on representing CHP from the launch to the return to Earth segments of the Artemis III and IV missions. Additionally, by incorporating the HRP Systems Platform for Aggregating and Relating Capabilities, or SPARC tool, the data from the programs was also related back to the 2nd volume of the NASA Human Health, Medical, and Performance Spaceflight Standard (NASA-STD-3001, Vol.2) and the human system risks identified by the Human System Risk Board (HSRB). The first version of the 2023 Artemis CHP system model was baselined in Fall of 2023 after the model was demonstrated to be a potentially useful tool for systems engineers integrating CHP capabilities in vehicle development as well as members of the Health and Medical Technical Authority providing oversight of those programs. The model may also be useful to any stakeholder of astronaut health and performance by providing insights on how an Artemis mission satisfies the NASA Human Health, Medical, and Performance Spaceflight Standards as well as how they mitigate the HSRB Human System Risks. This presentation highlights how the model was developed and the possible benefits of the model. [1] NASA HRP (2022), Crew Health and Performance System Whitepaper

Systems engineering↗

A knowledge-based system design/information tool for aircraft flight control systems

Research aircraft have become increasingly dependent on advanced control systems to accomplish program goals. These aircraft are integrating multiple disciplines to improve performance and satisfy research objectives. This integration is being accomplished through electronic control systems. Because of the number of systems involved and the variety of engineering disciplines, systems design methods and information management have become essential to program success. The primary objective of the system design/information tool for aircraft flight control system is to help transfer flight control system design knowledge to the flight test community. By providing all of the design information and covering multiple disciplines in a structured, graphical manner, flight control systems can more easily be understood by the test engineers. This will provide the engineers with the information needed to thoroughly ground test the system and thereby reduce the likelihood of serious design errors surfacing in flight. The secondary objective is to apply structured design techniques to all of the design domains. By using the techniques in the top level system design down through the detailed hardware and software designs, it is hoped that fewer design anomalies will result. The flight test experiences of three highly complex, integrated aircraft programs are reviewed: the X-29 forward-swept wing, the advanced fighter technology integration (AFTI) F-16, and the highly maneuverable aircraft technology (HiMAT) program. Significant operating anomalies and the design errors which cause them, are examined to help identify what functions a system design/information tool should provide to assist designers in avoiding errors.

Mackall, Dale A.↗

The Environment for Application Software Integration and Execution (EASIE), version 1.0. Volume 2: Program integration guide

The Environment for Application Software Integration and Execution, EASIE, provides a methodology and a set of software utility programs to ease the task of coordinating engineering design and analysis codes. EASIE was designed to meet the needs of conceptual design engineers that face the task of integrating many stand-alone engineering analysis programs. Using EASIE, programs are integrated through a relational data base management system. In volume 2, the use of a SYSTEM LIBRARY PROCESSOR is used to construct a DATA DICTIONARY describing all relations defined in the data base, and a TEMPLATE LIBRARY. A TEMPLATE is a description of all subsets of relations (including conditional selection criteria and sorting specifications) to be accessed as input or output for a given application. Together, these form the SYSTEM LIBRARY which is used to automatically produce the data base schema, FORTRAN subroutines to retrieve/store data from/to the data base, and instructions to a generic REVIEWER program providing review/modification of data for a given template. Automation of these functions eliminates much of the tedious, error prone work required by the usual approach to data base integration.

Jones, Kennie H.↗

Payload Utilization in NASA's Space Launch System

A revitalized National Space Council has directed NASA to return to the moon, with a series of preparatory missions paving the way for eventual human exploration. NASA's new deep space exploration system -- the heavy-lift Space Launch System (SLS), the Orion crew spacecraft and revitalized launch facilities at Kennedy Space Center -- will enable NASA and its commercial and international partners to meet these goals for human deep space exploration. SLS will be the most capable launch vehicle for these efforts, with an initial Block 1 capability of at least 26 metric tons (t) to trans-lunar injection (TLI). A more powerful Block 1B, available in crew and cargo configurations, with have the power to loft more than 37 t to TLI; the ultimate Block 2 variant will lift more than 45 t to TLI. For payload utilization, the Block 1 vehicle will carry 13 6U CubeSats as secondary payloads while the Block 1B crew vehicle will provide as much volume as the space shuttle payload bay in a Universal Stage Adapter (USA). Block 1B cargo vehicles will offer 8.4 m fairings in 19.1 m and 27.4 m lengths, with enough volume to accommodate habitat modules and landers. For missions beyond the Earth-moon system, SLS offers greater characteristic energy (C3), enabling faster transit or heavier payloads to the outer planets. The first mission of SLS and Orion, launching no earlier than December 2019, will send Orion into lunar distant retrograde orbit (DRO) on an approximately 25-day shakedown cruise known as Exploration Mission-1 (EM-1), enabling NASA to verify and validate new systems before sending astronauts to deep space on the next exploration mission. The SLS program and its prime contractors have made significant progress toward first launch, with several major components of the vehicle completed and delivered to the Exploration Ground Systems (EGS) Program at Kennedy Space Center. Major forward work includes integrating tanks, engines and other major sections into the EM-1 core stage at Michoud Assembly Facility and then shipping the entire core stage assembly to Stennis Space Center. There, it will be installed in the refurbished B-2 test stand for a series of integrated stage tests culminating in a green run hotfire test. The Program's Spacecraft Payload Integration and Evolution (SPIE) Office, responsible for the in-space stage, adapters and payload interfaces, has largely completed its effort on the Block 1 vehicle and is supporting manufacture of the first Block 1B vehicle. This paper will provide an overview of the Block 1 vehicle, its expected capabilities, secondary payload accommodations and manufacturing status, including structural testing and the challenges of developing a new launch vehicle. A lookahead to the Block 1B vehicle and the payload utilization opportunities it will provide in the 2020s will also be discussed, including the unique capabilities of the vehicle.

Creech, Stephen D.↗

Program document for Energy Systems Optimization Program 2 (ESOP2). Volume 1: Engineering manual

The Energy Systems Optimization Program, which is used to provide analyses of Modular Integrated Utility Systems (MIUS), is discussed. Modifications to the input format to allow modular inputs in specified blocks of data are described. An optimization feature which enables the program to search automatically for the minimum value of one parameter while varying the value of other parameters is reported. New program option flags for prime mover analyses and solar energy for space heating and domestic hot water are also covered.

Hamil, R. G.↗

Computational structural mechanics for engine structures

The computational structural mechanics (CSM) program at Lewis encompasses the formulation and solution of structural mechanics problems and the development of integrated software systems to computationally simulate the performance, durability, and life of engine structures. It is structured to supplement, complement, and, whenever possible, replace costly experimental efforts. Specific objectives are to investigate unique advantages of parallel and multiprocessing for reformulating and solving structural mechanics and formulating and solving multidisciplinary mechanics and to develop integrated structural system computational simulators for predicting structural performance, evaluating newly developed methods, and identifying and prioritizing improved or missing methods.

Chamis, Christos C.↗

Computational structural mechanics for engine structures

The computational structural mechanics (CSM) program at Lewis encompasses the formulation and solution of structural mechanics problems and the development of integrated software systems to computationally simulate the performance, durability, and life of engine structures. It is structured to supplement, complement, and, whenever possible, replace costly experimental efforts. Specific objectives are to investigate unique advantages of parallel and multiprocessing for reformulating and solving structural mechanics and formulating and solving multidisciplinary mechanics and to develop integrated structural system computational simulators for predicting structural performance, evaluating newly developed methods, and identifying and prioritizing improved or missing methods.

Chamis, Christos C.↗

Supersonic cruise research aircraft structural studies: Methods and results

NASA Langley Research Center SCAR in-house structural studies are reviewed. In methods development, advances include a new system of integrated computer programs called ISSYS, progress in determining aerodynamic loads and aerodynamically induced structural loads (including those due to gusts), flutter optimization for composite and metal airframe configurations using refined and simplified mathematical models, and synthesis of active controls. Results given address several aspects of various SCR configurations. These results include flutter penalties on composite wing, flutter suppression using active controls, roll control effectiveness, wing tip ground clearance, tail size effect on flutter, engine weight and mass distribution influence on flutter, and strength and flutter optimization of new configurations. The ISSYS system of integrated programs performed well in all the applications illustrated by the results, the diversity of which attests to ISSYS' versatility.

Sobieszczanski-Sobieski, J.↗

Practical Application of PRA as an Integrated Design Tool for Space Systems

This paper presents the application of the first comprehensive Probabilistic Risk Assessment (PRA) during the design phase of a joint NASA/NOAA weather satellite program, Geostationary Operational Environmental Satellite Series R (GOES-R). GOES-R is the next generation weather satellite primarily to help understand the weather and help save human lives. PRA has been used at NASA for Human Space Flight for many years. PRA was initially adopted and implemented in the operational phase of manned space flight programs and more recently for the next generation human space systems. Since its first use at NASA, PRA has become recognized throughout the Agency as a method of assessing complex mission risks as part of an overall approach to assuring safety and mission success throughout project lifecycles. PRA is now included as a requirement during the design phase of both NASA next generation manned space vehicles as well as for high priority robotic missions. The influence of PRA on GOES-R design and operation concepts are discussed in detail. The GOES-R PRA is unique at NASA for its early implementation. It also represents a pioneering effort to integrate risks from both Spacecraft (SC) and Ground Segment (GS) to fully assess the probability of achieving mission objectives. PRA analysts were actively involved in system engineering and design engineering to ensure that a comprehensive set of technical risks were correctly identified and properly understood from a design and operations perspective. The analysis included an assessment of SC hardware and software, SC fault management system, GS hardware and software, common cause failures, human error, natural hazards, solar weather and infrastructure (such as network and telecommunications failures, fire). PRA findings directly resulted in design changes to reduce SC risk from micro-meteoroids. PRA results also led to design changes in several SC subsystems, e.g. propulsion, guidance, navigation and control (GNC), communications, mechanisms, and command and data handling (C&DH). The fault tree approach assisted in the development of the fault management system design. Human error analysis, which examined human response to failure, indicated areas where automation could reduce the overall probability of gaps in operation by half. In addition, the PRA brought to light many potential root causes of system disruptions, including earthquakes, inclement weather, solar storms, blackouts and other extreme conditions not considered in the typical reliability and availability analyses. Ultimately the PRA served to identify potential failures that, when mitigated, resulted in a more robust design, as well as to influence the program's concept of operations. The early and active integration of PRA with system and design engineering provided a well-managed approach for risk assessment that increased reliability and availability, optimized lifecyc1e costs, and unified the SC and GS developments.

Kalia, Prince↗

Energy Efficient Engine Program: Technology Benefit/Cost Study, Volume II

The Benefit/Cost Study portion of the NASA-sponsored Energy Efficient Engine Component Development and Integration program was successful in achieving its objectives: identification of air transport propulsion system technology requirements for the years 2000 and 2010, and formulation of programs for developing these technologies. It is projected that the advanced technologies identified, when developed to a state of readiness, will provide future commercial and military turbofan engines with significant savings in fuel consumption and related operating costs. These benefits are significant and far from exhausted. The potential savings translate into billions of dollars in annual savings for the airlines. Analyses indicate that a significant portion of the overall savings is attributed to aerodynamic and structure advancements. Another important consideration in acquiring these benefits is developing a viable reference technology base that will permit engines to operate at substantially higher overall pressure ratios and bypass ratios. Results have pointed the direction for future research and a comprehensive program plan for achieving this was formulated. The next major step is initiating the program effort that will convert the advanced technologies into the expected benefits.

Gray, D. E.↗

Practical Application of Model-based Programming and State-based Architecture to Space Missions

Innovative systems and software engineering solutions are required to meet the increasingly challenging demands of deep-space robotic missions. While recent advances in the development of an integrated systems and software engineering approach have begun to address some of these issues, they are still at the core highly manual and, therefore, error-prone. This paper describes a task aimed at infusing MIT's model-based executive, Titan, into JPL's Mission Data System (MDS), a unified state-based architecture, systems engineering process, and supporting software framework. Results of the task are presented, including a discussion of the benefits and challenges associated with integrating mature model-based programming techniques and technologies into a rigorously-defined domain specific architecture.

state analysis↗

Measurement and Controls Data Acquisition System

Measurement and Controls Data Acquisition System (MCDAS) is an application program that integrates the functions of two stand-alone programs: one for acquisition of data, the other for controls. MCDAS facilitates and improves testing of complex engineering systems by helping to perform calibration and setup of test systems and acquisition, dissemination, and processing of data. Features of MCDAS include an intuitive, user-friendly graphical user interface, a capability for acquiring data at rates greater than previously possible, cooperation between the data-acquisition software subsystem and alarm-checking and analytical components of the control software subsystem, and a capability for dissemination of data through fiber optics and virtual and wide-area networks, including networks that contain hand-held display units. The integration of the data acquisition and control software offers a safety advantage by making alarm information available to the control software in a more timely manner. By enabling the use of hand-held devices, MCDAS reduces the time spent by technicians asking for screen updates to determine effects of setup actions. Previously recorded data can be processed without interruption to current acquisition of data. Analysts can continue to view test parameters while test-data files are being generated.

Hall, Rick↗

Energy efficient engine. Volume 1: Component development and integration program

Technology for achieving lower installed fuel consumption and lower operating costs in future commercial turbofan engines are developed, evaluated, and demonstrated. The four program objectives are: (1) propulsion system analysis; (2) component analysis, design, and development; (3) core design, fabrication, and test; and (4) integrated core/low spoon design, fabrication, and test.

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