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Maintainability Program Requirements for Space Systems

This document is established to provide common general requirements for all NASA programs to: design maintainability into all systems where maintenance is a factor in system operation and mission success; and ensure that maintainability characteristics are developed through the systems engineering process. These requirements are not new. Design for ease of maintenance and minimization of repair time have always been fundamental requirements of the systems engineering process. However, new or reusable orbital manned and in-flight maintainable unmanned space systems demand special emphasis on maintainability, and this document has been prepared to meet that need. Maintainability requirements on many NASA programs differ in phasing and task emphasis from requirements promulgated by other Government agencies. This difference is due to the research and development nature of NASA programs where quantities produced are generally small; therefore, the depth of logistics support typical of many programs is generally not warranted. The cost of excessive maintenance is very high due to the logistics problems associated with the space environment. The ability to provide timely maintenance often involves safety considerations for manned space flight applications. This document represents a basic set of requirements that will achieve a design for maintenance. These requirements are directed primarily at manned and unmanned orbital space systems. To be effective, maintainability requirements should be tailored to meet specific NASA program and project needs and constraints. NASA activities shall invoke the requirements of this document consistent with program planning in procurements or on inhouse development efforts.

Source record↗

Requirements for maintaining cryogenic propellants during planetary surface stays

Potential impacts on the planetary surface system infrastructure resulting from the use of liquid hydrogen and oxygen propellants for a stage and half lander are discussed. Particular attention is given to techniques which can be incorporated into the surface infrastructure and/or the vehicle to minimize the impact resulting from the use of these cryogens. Methods offered for reducing cryogenic propellant boiloff include modification of the lander to accommodate boiloff, incorporation of passive thermal control devices to the lander, addition of active propellant management, and use of alternative propellants.

Riccio, Joseph R.↗

An upfront R&M approach for aerospace systems

NASA has recently established a maintainability and maintenance planning program. This paper presents an overview of the program and discusses the specific application of the maintainability requirements as contained in NASA handbook (NHB) 5300.4 (1E), 'Maintainability Program Requirements for Space Systems'. Suggestions regarding the extent to which these requirements should be applied during each phase of program development also are presented.

Lisk, Ronald C.↗

Variable Structure PID Control to Prevent Integrator Windup

PID controllers are frequently used to control systems requiring zero steady-state error while maintaining requirements for settling time and robustness (gain/phase margins). PID controllers suffer significant loss of performance due to short-term integrator wind-up when used in systems with actuator saturation. We examine several existing and proposed methods for the prevention of integrator wind-up in both continuous and discrete time implementations.

Hall, C. E.↗

NASA Exploration Systems Maintainability Standards for Artemis and Beyond

This assessment was requested by the NASA Engineering and Safety Center (NESC), which, based on findings from the NESC study “Safe Human Expeditions Beyond Low Earth Orbit (LEO)” (Valinia et al., 2022), determined its topic to be an underrecognized critical and urgent Agency need, due to impending Artemis vehicle procurements. The principal objective of this assessment was to review and update current Agency-level maintainability requirements for space systems to support crew on expeditions beyond LEO in both preventive and corrective maintenance. This report contains the results of the NESC assessment.

Orbital Replacement Units↗

Evolution of the Space Station Robotic Manipulator

The Space Station Remote Manipulator System (SSRMS), Canadarm2, was launched in 2001 and deployed on the International Space Station (ISS). The Canadarm2 has been instrumental in ISS assembly and maintenance. Canadarm2 shares its heritage with the Space Shuttle Arm (Canadarm). This article explores the evolution from the Shuttle Canadarm to the Space Station Canadarm2 design, which incorporates a 7 degree of freedom design, larger joints, and changeable operating base. This article also addresses phased design, redundancy, life and maintainability requirements. The design of Canadarm2 meets unique ISS requirements, including expanded handling capability and the ability to be maintained on orbit. The size of ISS necessitated a mobile manipulator, resulting in the unique capability of Canadarm2 to relocate by performing a walk off to base points located along the Station, and interchanging the tip and base of the manipulator. This provides the manipulator with reach and access to a large part of the Station, enabling on-orbit assembly of the Station and providing support to Extra-Vehicular Activity (EVA). Canadarm2 is evolving based on on-orbit operational experience and new functionality requirements. SSRMS functionality is being developed in phases to support evolving ISS assembly and operation as modules are added and the Station becomes more complex. Changes to sustaining software, hardware architecture, and operations have significantly enhanced SSRMS capability to support ISS mission requirements. As a result of operational experience, SSRMS changes have been implemented for Degraded Joint Operations, Force Moment Sensor Thermal Protection, Enabling Ground Controlled Operations, and Software Commutation. Planned Canadarm2 design modifications include: Force Moment Accommodation, Smart Safing, Separate Safing, and Hot Backup. In summary, Canadarm2 continues to evolve in support of new ISS requirements and improved operations. It is a tribute to the design that this evolution can be accomplished while conducting critical on-orbit operations with minimal hardware changes.

Razvi, Shakeel↗

Effects of Above Real Time Training (ARTT) On Individual Skills and Contributions to Crew/Team Performance

Above Real Time Training (ARTT) is the training acquired on a real time simulator when it is modified to present events at a faster pace than normal. The experiments on training of pilots performed by NASA engineers and others have indicated that real time training (RTT) reinforced with ARTT would offer an effective training strategy for such tasks which require significant effort at time and workload management. A study was conducted to find how ARTT and RTT complement each other for training of novice pilot-navigator teams to fly on a required route. In the experiment, each of the participating pilot-navigator teams was required to conduct simulator flights on a prescribed two-legged ground track while maintaining required air speed and altitude. At any instant in a flight, the distance between the actual spatial point location of the airplane and the required spatial point was used as a measure of deviation from the required route. A smaller deviation represented better performance. Over a segment of flight or over complete flight, an average value of the deviation represented consolidated performance. The deviations were computed from the information on latitude, longitude, and altitude. In the combined ARTT and RTT program, ARTT at intermediate training intervals was beneficial in improving the real time performance of the trainees. It was observed that the team interaction between pilot and navigator resulted in maintaining high motivation and active participation throughout the training program.

Ali, Syed Firasat↗

Sustaining Thermal Protection Systems Needed for Uranus Probes

Summary: Achieving Uranus in-situ science objectives through deploying probes in the atmosphere requires thermal protection systems capable of withstanding extreme entry environments. NASA’s 3-D Woven based thermal protection systems (TPS), developed specifically to meet this challenge, are mature, efficient, and capable of withstanding such entry. These science-enabling capabilities need to be sustained, otherwise mission implementation risk may increase to the point that the mission is untenable. The heatshield technology has been developed in concert with industry, and manufacturing processes have been technology transferred. Current technology readiness does not guarantee future availability. Sustainment requires maintaining expertise within NASA as well as ensuring that proven industrial expertise and capabilities will be readily available in the future. A constant awareness and risk assessment followed by risk mitigation are required. The scientific community needs to be aware of these challenges. It needs to engage NASA to ensure these capabilities will be available when needed. As was the case with the atrophy of heritage carbon phenolic that led to developing the 3-D Woven capabilities, our vigilance is again needed to sustain these enabling TPS capabilities for Uranus and for other missions. Background: NASA invested in and developed Heatshield for Extreme Entry Environment Technology (HEEET) TPS that was matured to TRL 6 in 2019 as a tiled system with seams and gap-fillers. Manufacturing readiness included development of specialized looms, molding, and infusion processes using commercial partners. In support of the Mars Sample Return mission, a single-layer, seamless, single-piece variant referred to as 3MDCP (3-D woven Mid-Density Carbon-Phenolic) was developed and is limited to a 1.3m maximum diameter scale due to weaving width limitations of 80”. Molding techniques developed to transform a flat, 2”-thick 3-D woven preform into a sphere-cone shape prior to phenolic resin infusion has been demonstrated. A team at NASA Ames is currently working with industry to demonstrate infusion at full-scale. By 2026, 3MDCP will be at a high level of maturity in technical, manufacturing, and integration readiness as well as material characterization. HEEET and 3MDCP for Uranus Entry: Several system studies have evaluated and baselined 3-D Woven TPS for Uranus entry, both HEEET as well as 3MDCP. If the aeroshell carrying the descent probe is 1.3m or less, then 3MDCP is a very capable and the most mass-efficient choice. If the aeroshell is bigger than 1.3m diameter, then HEEET can meet the mission need as it allows for an aeroshell of any diameter. HEEET and 3MDCP are capable of Saturn in-situ science missions prioritized in the New Frontiers-5 draft Announcement of Opportunity (AO) and if Saturn is the mission of choice, there is a pathway for sustaining the capability. Capability Sustainment: Given NASA’s current budgetary constraints, the postponement of the next New Frontiers AO to no earlier than 2026 and the unknown delay in starting the UOP flagship effort point to potential gap years for the HEEET and 3MDCP capabilities. The first step in capability sustainment is to understand the risks as they emerge, assess those risks, and develop plans to mitigate them. Keeping the science community, who are interested in UOP as well as the larger Giant Planet missions, informed of the emerging challenges requires continuous risk assessment/mitigation. Without these steps, atrophy is more likely within the industrial partners with which NASA has partnered. This presentation will provide more details as well as steps NASA can take to minimize the impact to the UOP mission.

Ethiraj Venkatapathy↗

Insect contamination protection for laminar flow surfaces

The ability of modern aircraft surfaces to achieve laminar flow was well-accepted in recent years. Obtaining the maximum benefit of laminar flow for aircraft drag reduction requires maintaining minimum leading-edge contamination. Previously proposed insect contamination prevention methods have proved impractical due to cost, weight, or inconvenience. Past work has shown that insects will not adhere to water-wetted surfaces, but the large volumes of water required for protection rendered such a system impractical. The results of a flight experiment conducted by NASA to evaluate the performance of a porous leading-edge fluid discharge ice protection system operated as an insect contamination protections system are presented. In addition, these flights explored the environmental and atmospheric conditions most suitable for insect accumulation.

Croom, Cynthia C.↗

Atmosphere revitalization in the space station prototype.

The atmosphere revitalization group (ARG) for the space station prototype (SSP) environmental/thermal control and life support system (ETC/LSS) has been designed to meet a comprehensive set of requirements and constraints for a flight type mission. Design definition is for a modular vehicle temperature and humidity control subsystem, contaminant control equipment, a hydrogen depolarized cell CO2 concentrator, a water electrolysis oxygen generation subsystem, CO2 reduction equipment, and a pressure and composition control subsystem. Performance requirements are for support of a crew of six. Realistic leakage rates and metabolic activity cycles, cabin temperature selectability, and controlled cabin relative humidities are specified for the design. Operational aspects of the subsystem are discussed with emphasis given to the influence of a 180-day, maintainable requirement on system design. Consideration of flight vehicle type packaging, in flight maintenance, data management systems interface and fault detection capability, and electrical supply constraints is covered.

Trusch, R. B.↗

A noncontacting scanning photoelectron emission technique for bonding surface cleanliness inspection

Molecular contamination of bonding surfaces can drastically affect the bond strength that can be achieved and therefore the structural integrity and reliability of the bonded part. The presence of thin contaminant films on bonding surfaces can result from inadequate or incomplete cleaning methods, from oxide growth during the time between cleaning (such as grit blasting) and bonding, or from failure to properly protect cleaned surfaces from oils, greases, fingerprints, release agents, or deposition of facility airborne molecules generated by adjacent manufacturing or processing operations. Required cleanliness levels for desired bond performance can be determined by testing to correlate bond strength with contaminant type and quantity, thereby establishing the degree of contamination that can be tolerated based on the strength that is needed. Once the maximum acceptable contaminant level is defined, a method is needed to quantitatively measure the contaminant level on the bonding surface prior to bonding to verify that the surface meets the established cleanliness requirement. A photoelectron emission technique for the nondestructive inspection of various bonding surfaces, both metallic and nonmetallic, to provide quantitative data on residual contaminant levels is described. The technique can be used to scan surfaces at speeds of at least 30 ft/min using a servo system to maintain required sensor to surface spacing. The fundamental operation of the photoelectron emission sensor system is explained and the automated scanning system and computer data acquisition hardware and software are described.

Gause, Raymond L.↗

Correcting Thermal Deformations in an Active Composite Reflector

Large, high-precision composite reflectors for future space missions are costly to manufacture, and heavy. An active composite reflector capable of adjusting shape in situ to maintain required tolerances can be lighter and cheaper to manufacture. An active composite reflector testbed was developed that uses an array of piezoelectric composite actuators embedded in the back face sheet of a 0.8-m reflector panel. Each individually addressable actuator can be commanded from 500 to +1,500 V, and the flatness of the panel can be controlled to tolerances of 100 nm. Measuring the surface flatness at this resolution required the use of a speckle holography interferometer system in the Precision Environmental Test Enclosure (PETE) at JPL. The existing testbed combines the PETE for test environment stability, the speckle holography system for measuring out-of-plane deformations, the active panel including an array of individually addressable actuators, a FLIR thermal camera to measure thermal profiles across the reflector, and a heat source. Use of an array of flat piezoelectric actuators to correct thermal deformations is a promising new application for these actuators, as is the use of this actuator technology for surface flatness and wavefront control. An isogrid of these actuators is moving one step closer to a fully active face sheet, with the significant advantage of ease in manufacturing. No extensive rib structure or other actuation backing structure is required, as these actuators can be applied directly to an easy-to-manufacture flat surface. Any mission with a surface flatness requirement for a panel or reflector structure could adopt this actuator array concept to create lighter structures and enable improved performance on orbit. The thermal environment on orbit tends to include variations in temperature during shadowing or changes in angle. Because of this, a purely passive system is not an effective way to maintain flatness at the scale of microns over several meters. This technology is specifically referring to correcting thermal deformations of a large, flat structure to a specified tolerance. However, the underlying concept (an array of actuators on the back face of a panel for correcting the flatness of the front face) could be extended to many applications, including energy harvesting, changing the wavefront of an optical system, and correcting the flatness of an array of segmented deployable panels.

Bradford, Samuel C.↗

Evolving Reliability and Maintainability Allocations for NASA Ground Systems

This paper describes the methodology that was developed to allocate 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. Allocating is an iterative process; as systems moved beyond their conceptual and preliminary design phases this provided an opportunity for the reliability engineering team to reevaluate allocations based on updated designs and maintainability characteristics of the components. Trade-offs in reliability and maintainability were essential to ensuring the integrity of the reliability and maintainability analysis. This paper will discuss the value of modifying reliability and maintainability allocations made for the GSDO subsystems as the program nears the end of its design phase.

allocations↗

Evolving Reliability and Maintainability Allocations for NASA Ground Systems

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.

reliability↗

Evolving Reliability and Maintainability Allocations for NASA Ground Systems

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.

allocations↗

An airline study of advanced technology requirements for advanced high speed commercial transport engines. 2: Engine preliminary design assessment

The advanced technology requirements for an advanced high speed commercial transport engine are presented. The results of the phase 2 study effort cover the following areas: (1) general review of preliminary engine designs suggested for a future aircraft, (2) presentation of a long range view of airline propulsion system objectives and the research programs in noise, pollution, and design which must be undertaken to achieve the goals presented, (3) review of the impact of propulsion system unreliability and unscheduled maintenance on cost of operation, (4) discussion of the reliability and maintainability requirements and guarantees for future engines.

Sallee, G. P.↗

Thermal design and development of a planetary probe - Pioneer Venus large probe

The thermal control system developed for the Large Atmospheric Probe of the Pioneer Venus Multiprobe Mission is described. The scope of the thermal control task requires maintaining the probe internal equipment shelf temperatures within a nonoperating range of -40 to 122 F and an operating range of -4 to 122 F during three different mission phases: (1) preseparation, the transit phase of the mission when the probe is attached to the Multiprobe Spacecraft Bus, (2) postseparation, the free-flight cruise phase of the mission following release from the Bus, and (3) descent, the phase of the mission from preentry equipment turn-on to impact on the Venus surface. Thermal control for these phases is achieved by a combination of passive thermal finishes on the probe exterior surfaces and heaters mounted on the equipment shelves. Verification of the adequacy of the total thermal design to meet all mission requirements has been completed.

Hennis, L. A.↗