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Control system testing

A three stage process of ground testing of the Space Telescope Pointing Control System is used for verification prior to on-orbit operation. First, development tests are conducted in a laboratory environment using flight/engineering model control sensor and actuators configured with an engineering model of the flight computer and data management system breadboards. These development tests validate the results of computer simulations predicting control system performance. Integration tests bring together flight system elements and software interfaced to a software simulation of vehicle dynamics to confirm closed loop performance. The final ground test phase, flight systems testing, is conducted on the fully assembled Space Telescope, verifies interfaces with the Fine Guidance Sensors and includes a thermal vacuum testing period. During the final test phase, the Point Control System is exercised with the dynamics simulator running in real time.

Whittler, W. H.

Testing Flight Systems with Machine Executable Scripts

The MSAP project at JPL has been testing spacecraft avionics and flight software since 2005, in part using computer executable scripts. The scripts are document files of a common word processor and comply with the format of a traditional, formal test procedure common at JPL. These procedures use keywords to issue commands and evaluate responses, mimicking a human test operator. In effect, script lines are inserted into a normal procedure. Even though the executable structure of the procedures is limited to linear sequences of fairly simple operations, we have found significant value in certain test regimes given the repeatability, ease of execution, and readily understandable intent of these procedures.

Gibbs, Don

Fault-Tolerant Software For Flight Control

Report discusses design and testing of redundant control system for F-8 digital fly-by-wire airplane. Outstanding feature of system is fault-tolerant software (REBUS) residing in primary digital computers. Transition to operation on backup software smooth.

Deets, Dwain A.

XML: James Webb Space Telescope Database Issues, Lessons, and Status

This paper will present the current concept using extensible Markup Language (XML) as the underlying structure for the James Webb Space Telescope (JWST) database. The purpose of using XML is to provide a JWST database, independent of any portion of the ground system, yet still compatible with the various systems using a variety of different structures. The testing of the JWST Flight Software (FSW) started in 2002, yet the launch is scheduled for 2011 with a planned 5-year mission and a 5-year follow on option. The initial database and ground system elements, including the commands, telemetry, and ground system tools will be used for 19 years, plus post mission activities. During the Integration and Test (I&T) phases of the JWST development, 24 distinct laboratories, each geographically dispersed, will have local database tools with an XML database. Each of these laboratories database tools will be used for the exporting and importing of data both locally and to a central database system, inputting data to the database certification process, and providing various reports. A centralized certified database repository will be maintained by the Space Telescope Science Institute (STScI), in Baltimore, Maryland, USA. One of the challenges for the database is to be flexible enough to allow for the upgrade, addition or changing of individual items without effecting the entire ground system. Also, using XML should allow for the altering of the import and export formats needed by the various elements, tracking the verification/validation of each database item, allow many organizations to provide database inputs, and the merging of the many existing database processes into one central database structure throughout the JWST program. Many National Aeronautics and Space Administration (NASA) projects have attempted to take advantage of open source and commercial technology. Often this causes a greater reliance on the use of Commercial-Off-The-Shelf (COTS), which is often limiting. In our review of the database requirements and the COTS software available, only very expensive COTS software will meet 90% of requirements. Even with the high projected initial cost of COTS, the development and support for custom code over the 19-year mission period was forecasted to be higher than the total licensing costs. A group did look at reusing existing database tools and formats. If the JWST database was already in a mature state, the reuse made sense, but with the database still needing to handing the addition of different types of command and telemetry structures, defining new spacecraft systems, accept input and export to systems which has not been defined yet, XML provided the flexibility desired. It remains to be determined whether the XML database will reduce the over all cost for the JWST mission.

Detter, Ryan

Flight Test of a Propulsion-Based Emergency Control System on the MD-11 Airplane with Emphasis on the Lateral Axis

A large, civilian, multi-engine transport MD-11 airplane control system was recently modified to perform as an emergency backup controller using engine thrust only. The emergency backup system, referred to as the propulsion-controlled aircraft (PCA) system, would be used if a major primary flight control system fails. To allow for longitudinal and lateral-directional control, the PCA system requires at least two engines and is implemented through software modifications. A flight-test program was conducted to evaluate the PCA system high-altitude flying characteristics and to demonstrate its capacity to perform safe landings. The cruise flight conditions, several low approaches and one landing without any aerodynamic flight control surface movement, were demonstrated. This paper presents results that show satisfactory performance of the PCA system in the longitudinal axis. Test results indicate that the lateral-directional axis of the system performed well at high attitude but was sluggish and prone to thermal upsets during landing approaches. Flight-test experiences and test techniques are also discussed with emphasis on the lateral-directional axis because of the difficulties encountered in flight test.

Burken, John J.

Human-rated Safety Certification of a High Voltage Robonaut Lithium-ion Battery

NASA's rigorous certification process is being followed for the R2 high voltage battery program for use of R2 on International Space Station (ISS). Rigorous development testing at appropriate levels to credible off-nominal conditions and review of test data led to design improvements for safety at the virtual cell, cartridge and battery levels. Tests were carried out at all levels to confirm that both hardware and software controls work. Stringent flight acceptance testing of the flight battery will be completed before launch for mission use on ISS.

Jeevarajan, Judith

James Webb Space Telescope Integrated Science Instrument Module Thermal Vacuum Thermal Balance Test Campaign at NASA's Goddard Space Flight Center

The James Webb Space Telescope is a large infrared telescope with a 6.5-meter primary mirror, designed as a successor to the Hubble Space Telescope when launched in 2018. Three of the four science instruments contained within the Integrated Science Instrument Module (ISIM) are passively cooled to their operational temperature range of 36K to 40K with radiators, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. Thermal-vacuum testing of the flight science instruments at the ISIM element level has taken place in three separate highly challenging and extremely complex thermal tests within a gaseous helium-cooled shroud inside Goddard Space Flight Centers Space Environment Simulator. Special data acquisition software was developed for these tests to monitor over 1700 flight and test sensor measurements, track over 50 gradients, component rates, and temperature limits in real time against defined constraints and limitations, and guide the complex transition from ambient to final cryogenic temperatures and back. This extremely flexible system has proven highly successful in safeguarding the nearly $2B science payload during the 3.5-month-long thermal tests. Heat flow measurement instrumentation, or Q-meters, were also specially developed for these tests. These devices provide thermal boundaries o the flight hardware while measuring instrument heat loads up to 600 mW with an estimated uncertainty of 2 mW in test, enabling accurate thermal model correlation, hardware design validation, and workmanship verification. The high accuracy heat load measurements provided first evidence of a potentially serious hardware design issue that was subsequently corrected. This paper provides an overview of the ISIM-level thermal-vacuum tests and thermal objectives; explains the thermal test configuration and thermal balances; describes special measurement instrumentation and monitoring and control software; presents key test thermal results; lists problems encountered during testing and lessons learned.

JWST ISIM Thermal

Atmosphere Explorer control system software (version 1.0)

The basic design is described of the Atmosphere Explorer Control System (AECS) software used in the testing, integration, and flight contol of the AE spacecraft and experiments. The software performs several vital functions, such as issuing commands to the spacecraft and experiments, receiving and processing telemetry data, and allowing for extensive data processing by experiment analysis programs. The major processing sections are: executive control section, telemetry decommutation section, command generation section, and utility section.

Villasenor, A.

Full-envelope aerodynamic modeling of the Harrier aircraft

A project to identify a full-envelope model of the YAV-8B Harrier using flight-test and parameter identification techniques is described. As part of the research in advanced control and display concepts for V/STOL aircraft, a full-envelope aerodynamic model of the Harrier is identified, using mathematical model structures and parameter identification methods. A global-polynomial model structure is also used as a basis for the identification of the YAV-8B aerodynamic model. State estimation methods are used to ensure flight data consistency prior to parameter identification.Equation-error methods are used to identify model parameters. A fixed-base simulator is used extensively to develop flight test procedures and to validate parameter identification software. Using simple flight maneuvers, a simulated data set was created covering the YAV-8B flight envelope from about 0.3 to 0.7 Mach and about -5 to 15 deg angle of attack. A singular value decomposition implementation of the equation-error approach produced good parameter estimates based on this simulated data set.

Mcnally, B. David

Software Tool for Tracking & Mapping the NASA Orion AA-2 Test Flight Ejectable Data Recorders in Real Time

On 2 July 2019, the NASA Ascent Abort 2 flight took place off the Florida coast to test the emergency systems to separate the Orion Crew Module (CM) from the future Space Launch System rocket in the event of a malfunction. During this high-altitude test, instrumentation data was recorded on twelve customized buoyant Ejectable Data Recorders (EDRs) and subsequently jettisoned from the CM in mid-air. Upon release, the EDRs activated their GPS-Iridium beacon systems and began transmitting Short Burst Data (SBD) messages via the Iridium satellite network to relay their individual location and system health information. To locate, track and retrieve each EDR from the ocean surface in real-time, multiple open-source programming tools (Python and Linux shells) were developed for parsing the incoming Iridium binary SBD messages. For this, a Linux laptop was used to receive the Iridium-generated emails containing the SBD messages and autonomously execute the parsing tools. The received SBD data contained location, timestamp and health status information that was translated, saved, and subsequently used for simultaneously generating a continuously updated color-coded tabular display summary and unique KML files used with Google Earth to track their locations. Once their locations were known, dedicated recovery vessels retrieved all EDRs from the ocean. An additional tool was also developed in order to generate 5- and 10-minute geolocation predictions for each EDR by deriving the displacement distance, elapsed time, displacement heading and velocity based on the latest known information available. The recovery vessels were also tracked with the use of a separate commercial GPS beacon system. After jettison, 67% of the EDRs transmitted valid data by the time they were retrieved from the ocean. However, the real-time information presented by the plotting tool allowed for the ready depiction of EDR dispersal patterns and reference drift trajectories, which contributed to the recovery of all twelve EDRs and the AA-2 flight data. Lastly, the available data showed that the distance between the software’s reported drift/predicted locations and the recovery locations did not exceed 38 meters, therefore demonstrating the advantages of this software tool for supporting real-time tracking and recovery efforts of beacon devices.

Moxey, Lucas

An experiment in software reliability

The results of a software reliability experiment conducted in a controlled laboratory setting are reported. The experiment was undertaken to gather data on software failures and is one in a series of experiments being pursued by the Fault Tolerant Systems Branch of NASA Langley Research Center to find a means of credibly performing reliability evaluations of flight control software. The experiment tests a small sample of implementations of radar tracking software having ultra-reliability requirements and uses n-version programming for error detection, and repetitive run modeling for failure and fault rate estimation. The experiment results agree with those of Nagel and Skrivan in that the program error rates suggest an approximate log-linear pattern and the individual faults occurred with significantly different error rates. Additional analysis of the experimental data raises new questions concerning the phenomenon of interacting faults. This phenomenon may provide one explanation for software reliability decay.

Dunham, J. R.

Feasibility of using a knowledge-based system concept for in-flight primary flight display research

A study was conducted to determine the feasibility of using knowledge-based systems architectures for inflight research of primary flight display information management issues. The feasibility relied on the ability to integrate knowledge-based systems with existing onboard aircraft systems. And, given the hardware and software platforms available, the feasibility also depended on the ability to use interpreted LISP software with the real time operation of the primary flight display. In addition to evaluating these feasibility issues, the study determined whether the software engineering advantages of knowledge-based systems found for this application in the earlier workstation study extended to the inflight research environment. To study these issues, two integrated knowledge-based systems were designed to control the primary flight display according to pre-existing specifications of an ongoing primary flight display information management research effort. These two systems were implemented to assess the feasibility and software engineering issues listed. Flight test results were successful in showing the feasibility of using knowledge-based systems inflight with actual aircraft data.

Ricks, Wendell R.

Bantam System Technology Project Ground System Requirements Document

The Low Cost Booster Project (LCBP), also known as Bantam, is an element of the Advanced Space Transportation Program focused on Low Cost Booster Technologies. During FY 99 flight demonstrations are planned to demonstrate the feasibility of producing a booster capable of inserting a 150 kg payload into low earth orbit. The ground support system is an element of the full launch system. The ground support system provides for integration of the payload with the launch vehicle, preparation of the vehicle for launch (including maintenance, integration and test of the vehicle flight software), monitor and control of the launch sequence, range safety during launch, and collection of telemetry during the flight up to payload release. The ground support system is intended to make the maximum possible use of Government Off-the-Shelf (GOTS) or Commercial Off-the-Shelf (COTS) hardware and software to obtain the best value in terms of development operations support and ultimate life cycle cost for the launch system.

Moon, J. M.

NASA IV&V's Cyber Range for Space Systems

A cyber range is a virtual environment that is used for cyberwarfare training and cyber technology development. It provides tools that help strengthen the stability, security and performance of cyber infrastructures and IT systems. NASA IV&V has created an adaptable virtual environment that is representative of a typical NASA mission system of systems environment that serves multiple purposes: Training of network defenders. Ability to perform simulated red vs blue training events. Ability to deploy mission specific technologies in a cyber contested environment. Ability to demonstrate vulnerabilities and their impact to ground and space systemsThe overall system is comprised of more than 70 virtual machines and physical infrastructure to demonstrate real-world cyber attacks against: email users, wireless networks, and physically implanted devices with command and control call-back. The cyber range was built to emulate a NASA precipitation satellite infrastructure.This presentation will give an overview of the virtual cyber range and how it was used to conduct a simulate red vs blue exercise with the goal of compromising the simulated spacecraft that utilizes real NASA flight software.

test and evaluation DT&E

Test Telemetry And Command System (TTACS)

The Jet Propulsion Laboratory has developed a multimission Test Telemetry and Command System (TTACS) which provides a multimission telemetry and command data system in a spacecraft test environment. TTACS reuses, in the spacecraft test environment, components of the same data system used for flight operations; no new software is developed for the spacecraft test environment. Additionally, the TTACS is transportable to any spacecraft test site, including the launch site. The TTACS is currently operational in the Galileo spacecraft testbed; it is also being provided to support the Cassini and Mars Surveyor Program projects. Minimal personnel data system training is required in the transition from pre-launch spacecraft test to post-launch flight operations since test personnel are already familiar with the data system's operation. Additionally, data system components, e.g. data display, can be reused to support spacecraft software development; and the same data system components will again be reused during the spacecraft integration and system test phases. TTACS usage also results in early availability of spacecraft data to data system development and, as a result, early data system development feedback to spacecraft system developers. The TTACS consists of a multimission spacecraft support equipment interface and components of the multimission telemetry and command software adapted for a specific project. The TTACS interfaces to the spacecraft, e.g., Command Data System (CDS), support equipment. The TTACS telemetry interface to the CDS support equipment performs serial (RS-422)-to-ethernet conversion at rates between 1 bps and 1 mbps, telemetry data blocking and header generation, guaranteed data transmission to the telemetry data system, and graphical downlink routing summary and control. The TTACS command interface to the CDS support equipment is nominally a command file transferred in non-real-time via ethernet. The CDS support equipment is responsible for metering the commands to the CDS; additionally for Galileo, TTACS includes a real-time-interface to the CDS support equipment. The TTACS provides the basic functionality of the multimission telemetry and command data system used during flight operations. TTACS telemetry capabilities include frame synchronization, Reed-Solomon decoding, packet extraction and channelization, and data storage/query. Multimission data display capabilities are also available. TTACS command capabilities include command generation verification, and storage.

Fogel, Alvin J.

Digital Fly-By-Wire Flight Control Validation Experience

The experience gained in digital fly-by-wire technology through a flight test program being conducted by the NASA Dryden Flight Research Center in an F-8C aircraft is described. The system requirements are outlined, along with the requirements for flight qualification. The system is described, including the hardware components, the aircraft installation, and the system operation. The flight qualification experience is emphasized. The qualification process included the theoretical validation of the basic design, laboratory testing of the hardware and software elements, systems level testing, and flight testing. The most productive testing was performed on an iron bird aircraft, which used the actual electronic and hydraulic hardware and a simulation of the F-8 characteristics to provide the flight environment. The iron bird was used for sensor and system redundancy management testing, failure modes and effects testing, and stress testing in many cases with the pilot in the loop. The flight test program confirmed the quality of the validation process by achieving 50 flights without a known undetected failure and with no false alarms.

Szalai, K. J.

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