Aerospace Power, Propulsion, and Electronics



Health Monitoring of Rocket Engines

Deepak Chadha and Ben H. Jansen, Ph.D. Department of Electrical Engineering

Techniques are being developed for on-line monitoring of complex, nonlinear systems, such as rocket engines. The primary aim is to detect impending failures in a timely manner so that catastrophic failure can be avoided. The basic concept involves training artificial neural networks (ANN) to accurately predict future values of sensor data from past and present observations. Researchers hypothesize that a successfully trained network captures the dynamics of the system from which sensor data are obtained. When the predicted values start to deviate from actual sensor data, monitors have an early sign that the underlying dynamics have changed and that the engine may be close to failing.

Two ANN architectures have been explored, the multi-layer perceptron (MLP) and the cascade correlation network (CCN). Two criteria were examined as a means of detecting change, the Total Sum of Squares (TSS) and the Weight Difference (WD). Research focused on determining the sensitivity of the proposed method using artificially generated data. Duffing's oscillator was used to produce chaotic time series sufficiently complicated that they appeared to be "stochastic" time series. Findings concluded that an MLP with ten hidden units operates better than a comparable CCN.

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Architecture and Composition of the Space Station Electrical Power System Module

Ovidiu Crisan, Ph.D., Department of Electrical Engineering

Present and future developments of the U. S. space program which include three important and difficult tasks-the Space Station, the return voyage to the moon, and a journey to Mars-are heavily dependent on space research achievements. Along with other objectives, advanced spacecraft require the implementation of large electrical power systems. Thus, autonomous power system control and management technology are needed to increase productivity and reliability and decrease human involvement and cost.

Substantial progress has been made in the last few years, with the NASA-Marshall Space Center being a leading contributor in the field. In 1987, NASA-JSC initiated a program to study Advanced Electrical Power Management Techniques for the Space Systems (ADEPTS). New research directions, procedures, and methods are needed for JSC to advance the level of technology. The solution calls for the utilization of multidisciplinary and high-level theoretical and practical skills. The spacecraft electrical power system is a complex subsystem which must operate in concert with other subsystems and payloads and for which human monitoring and control are very difficult and costly.

Main tasks of the research are to define the spacecraft's power system configuration, to define and model the operation, automation and control function for each of its components, to define and model the monitoring, measurement, control and management functions of the spacecraft main computer and, for an average daily cycle, by computer to model and analyze the spacecraft's normal and possible faulty states. Proposals are drawn to improve the structure and functions of the spacecraft.

The researchers are currently working on a new module for the space station electrical power system (EPS), focusing on (1) EPS components modeling and EPS computer implementation, (2) computers, computer network, and interface selection and implementation , and (3) the definition of load and control management of the spacecraft Electrical Power Distribution and Control Systems (EPDCS) and implementation. The Power Control and Management System (PCMS) must have a monitoring system and a proper interface with higher level operation management systems and must allow for easy expansion and the inclusion of other expert system decision processes.

Designers of the module are considering problems of energy collection and conversion, energy storage, power conversion, power distribution, and electrical power consuming equipment.

Each of the main components of the spacecraft electrical power system has been modeled and system operations tested in six areas: 1) energy collection and conversion, 2) energy storage, 3) power conversion, 4) power distribution, 5) management and control, and 6) grounding and protection subsystems.

Results show that for tasks of the main computer, mainly related to monitoring, measurement, and economic dispatch, there is a need for a more complete definition. Also, the time coordination of the protection system must be improved and possible multiple faults modeled. To quantitatively define the overall performances of the system for a given time-cycle, the states probability should be counted.

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Monitoring of Aerospace Structures

Robert D. Finch, Ph.D. Department of Mechanical Engineering

Acoustic signals can be used to monitor the integrity of construction facilities. Research seeks to improve the resolution of defect detection by such systems. A system for the detection of defects consists of an acoustic excitation, a transmission path, one or more receivers, and hardware for signal processing and computation. Current research involves three disciplines: (1) modeling of the monitored systems, (2) data acquisition and signal processing, and (3) system identification.

The monitoring of structural composite beams and panels, as intended for aerospace applications, may be considered a specific example. In modeling, the concern is to develop computational techniques that are not only accurate but also efficient enough to permit their being used as part of a software package for real-time recognition. In data acquisition and signal processing, researchers seek the optimization of present techniques and the development of new ones. For this purpose, this laboratory is developing a database from experiments with beams and panels under a variety of conditions in a test stand constructed specifically for this purpose. In system identification, the objective is the classification of objects (as good, defective, etc.) from their received signals, using techniques from pattern recognition, artificial neural nets, and inverse techniques based upon ISSO modeling studies.

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Knowledge-Based Fault Detection and Recovery in Power Distribution Systems

Sven G. Holmquist and Prahash Jayaram, graduate students; Ben H. Jansen, Ph.D., Department of Electrical Engineering

A control system is being developed for autonomous distribution and control of electrical power systems using an object-oriented simulation model of the power system and first-principle knowledge to detect, identify, and isolate faults. Each power system component is represented as a separate object with knowledge of its normal behavior.

The reasoning process takes place at two different levels of abstraction: the Physical Component Model (PCM) level and the Electrical Equivalent Model (EEM) level, with the PCM being the lowest level of abstraction and the EEM the highest. At the EEM level, power system components are reasoned in terms of their electrical equivalents (e.g., a resistive load is thought of as a resistor). At the PCM level, however, detailed knowledge about the component's specific characteristics is taken into account.

The control system operates in two simultaneous modes, a reactive and a proactive mode. In the reactive mode, the control system receives measurement data from the power system and compares these values with values determined through simulation to detect the existence of a fault. The nature of the fault is then identified through a model-based reasoning process mainly using the EEM. Compound component models are constructed at the EEM level and are used in the fault identification process. In the proactive mode, reasoning takes place at the PCM level. Individual components determine their future health status utilizing a physical model and measured historical data. If changes in health status seem imminent, the component warns the control system about its impending failure.

During the past year, researchers completed the following projects:

The VIsolver was refined and tested for "larger" cases. The VIsolver is an object that solves for currents and voltages of the power system using the modified nodal formulation. This method can be used on networks containing voltage and current sources, impedances, conductances, ideal two-ports, and switches.

The fault identification method-(the process of determining which component or components caused the failure-has been modified. The concept of compound components has been introduced to solve the problem of insufficient sensory information. Compound components are models of several EEM's in series, parallel, or in a bridge configuration combined into a single model component. The location of the available current-meters and volt-meters guides the formation of the compound components so that in the (reduced) environment the impedance of each compound component can be calculated based on sensor data.

Models for some typical power systems components; e.g., generic solar panels and batteries, based on first-principle knowledge, operating characteristics, and heuristics.

Development of the framework for concurrent hypothesis testing. The fault detection method conceptualized is based on the generation and simultaneous pursuit of several possible causes (hypotheses) for the misbehavior of the power system. Each of these hypotheses will spawn a separate process, which will terminate when it has been established that the hypothesis cannot be the cause of the problem. This approach leads to a very efficient implementation on a multi-processor machine.

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Superconducting Quantum Interference Gratings

John Harris Miller, Jr., Ph.D., the Texas Center for Superconductivity, TCSUH and Gemunu Gunaratne, Ph.D., Department of Physics

Miller and GunaratneInterferometers were fabricated consisting of arrays with several grain boundary junctions (GBJ's) in parallel, by patterning 1400 Å thick YBa2Cu3O7-x (YBCO) films laser deposited onto SrTiO3 (STO) bi-crystal substrates with 24&degree; misorientation angles. The width of each junction was 5 mm and the dimensions of each loop in the array were 10 mm x 50 mm. The self-inductance parameters of the devices were estimated to be b = 2LIc1/I = 14 at 77 K and even higher at lower temperatures. The magnetic field-dependence of the critical current is shown in Figure 1 for a 6-junction interferometer at 77 K. Initially, after cooling the sample in zero field, the critical current decreases with increasing field and exhibits small oscillations, eventually saturating at a small residual value. When the direction of the field sweep is reversed, a pronounced "satellite" peak is observed as the field is decreased towards zero. If one continues to sweep the field in the negative direction and then reverses the direction of the field sweep again, another satellite peak, which is roughly the mirror image of the first is observed as the field is swept in the positive direction towards the origin. Additional sweeps in the positive and negative directions yield only the satellite peaks, whereas the central maximum at zero field, Ic (H = 0), remains suppressed until the sample is warmed up above Tc and cooled down again in zero field. This is somewhat similar to the hysteretic behavior observed in the field-dependent critical current of granular Nb microbridges (Aumine et al., 1989).

Figure 1. Critical current vs. field fo a 6 JJ array at 77K, with a sweep range of -2 gauss to +2 gauss (neglecting flux focusing effects). The magnetic field begins at zero (at the center) and is slowly incresed to its maximum positive value (at the right). The sweep direction is then reversed and the magnetic field is slowly decreaded to its maximum negative value (at the left). Finally, the field is slowly swept back to zero.

The separation between the satellite peaks is found to increase with increasing sweep range, or maximum applied field Hmax. However, the difference DH* = |Hmax - Hpeak| between each extreme of the field sweep and the position of each satellite peak is roughly independent of Hmax for a given temperature, provided the maximum field is sufficiently high that the condition |Hmax| > 2DH* is satisfied. The value of DH* thus appears to be related to the field required for the system to reach the critical state, in which the screening current flowing through each junction is about equal to the junction critical current.

A one-dimensional (1D) parallel JJ array, or interferometer, with large B can be represented by a Hamiltonian formally identical to the Frenkel-Kontorova (FK) model (Frenkel and Kontorova, 1938, 1939) of spring-coupled balls in a washboard potential or, equivalently, pendula in a gravitational potential coupled by torsion springs. The FK model has been utilized to describe numerous physical systems, including metastable states in pinned charge-density waves with internal degrees of freedom (Coppersmith, 1987). The existence of irreversibility and critical state behavior in the field-dependent flux profiles of 1D JJ arrays has been modeled by Parodi and Vaccarone (Parodi and Vaccarone, 1991). In the limit of large B, each loop in the array can trap several flux quanta and the system is predicted to exhibit hysteresis in the magnetic behavior (Majhofer et al., 1991), by analogy to the critical state model of type-II superconductors (Bean, 1962).

Initially, as the externally applied flux fx is increased from zero, screening currents flowing through the junctions screen out most of the flux from the interior. When the screening currents flowing through the two end junctions reach their corresponding critical currents, flux starts to penetrate into the outer loops. As the applied field is increased further, flux (= LIc1 per loop) penetrates into each loop one-by-one until a "critical state" is attained, in which flux has penetrated all the way into the interior loops of the array, and the (negative) magnetization M = <0 - 0x>/[µ0 x loop area] has saturated to its maximum magnitude. In the FK model, this is equivalent to stretching (or compressing) all of the springs to the point where the restoring force acting on each ball in the washboard potential is maximum. If the field is then decreased, flux "leaks out" of each loop one-by-one until opposite critical state is attained, in which the trapped flux remaining in the loops is maximum (= NLIc1/2) in the middle of the array and decreases towards the ends. A plot of M vs. field H thus forms a hysteresis loop, just as in the critical state model.

The total magnetization of the array is proportional to the net circulating current. One would therefore expect the critical current to be a maximum whenever the net circulating current, and thus the magnetization, is equal to zero during an M-H hysteresis loop. According to this argument, &Delta;H* would be constant and about equal to the remnant magnetization, Mrem = NLIc1/ (2µ0Aloop), provided the maximum applied field was sufficiently high that the critical state was maintained throughout the field sweep cycle, i.e. Hmax > 2Mrem. This result would be consistent with the experiment, and would account for the observed shift in satellite peak position with increasing sweep range in plots of Ic vs. H.

References
Aumine J., E. Tanaka, S. Yamasaki, K. Tani, and A. Yonekura. "Hysteresis of Critical Currents of Superconducting Bridges in Low Perpendicular Magnetic Fields." J. Low Temp. Phys. 74 (1989): 263-275.
Bean, C.P. "Magnetization of Hard Superconductors." Phys. Rev. Lett.,8 (1962): 250-253.
Coppersmith, S.N. "Overdamped Frenkel -Kotorova Model with Randomness as a Dynamic System: Mode Locking and Derivation of Discrete Maps." Phys. Rev. A.36 (1987): 3375-82.
Frenkel, J. and T. Kontorova, "On the Theory of Plastic Demortation and Twinning," Zh. Eksp. Teor. Fiz 8 (1938):1340; J. Phys. [Moscow] (1939): 137.
Majhofer, A., T. Wolf, and W. Dietrich. "Irreversible Magnetization Effects in a Network of Resistively Shunted Tunnel Junctions." Phys. Rev.B. 44 (1991): 9634-38.
Parodi, F. and R. Vaccarone. "Critical State and Flux Dynamics in Squid Arrays." Physica C. 173(1991): 56-64.

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Fracture of Solid Propellants

Krishnaswamy Ravi-Chandar, Ph.D., and Shalini Gupta, graduate researcher, Department of Mechanical Engineering

While the fracture mechanics of viscoelastic solids has been studied over the past decades, problems remain in the application of the theory to solid propellants. This program served to investigate the details of stress and deformation fields near the crack tip using the method of Electronic Speckle Pattern Interferometry (ESPI), as a prelude to the development of techniques that will prove useful in the characterization of the fracture behavior of solid propellants.

The basic idea of the ESPI is similar to that of any two-beam interferometry. The two light beams that interfere are, however, obtained from a diffusely reflecting surface. This result implies that no special preparation of the specimen surface is necessary. The image obtained is "speckled"; that is, it appears grainy. The speckle intensity pattern initially generated before displacement of the reflecting surface, can be correlated to the speckle pattern produced after displacement. If the initial speckle pattern is stored as a digital image and then subtracted from speckle pattern after displacement, an EPSI image is produced that can be correlated to the displacement. By properly choosing the relative orientations of the two illuminating beams and the angle of observation of the speckle patterns, in-plane and out-of-plane components of the displacement can be obtained separately.

The sensitivity of the technique can also be altered easily by varying the same parameters, thus making the speckle technique more flexible compared with other interferometric techniques. The implementation of the method of ESPI to solid propellant does not require any surface preparation since the solid propellant surface is already "speckly." ESPI was implemented using a DATA Translation frame grabber on an IBM/PC; the frame grabber permits real time implementation of the processing of ESPI. A digitized 8-bit image is passed through an input look-up table and transformed into a 4-bit image and stored in the lower four bits of an 8-bit frame storage memory; this image is the first speckle image.

The second digitized image, which is acquired continuously, is passed through another look-up table that transforms the image into a 4-bit image stored in the upper four bits of the same 8-bit frame storage memory. The two four-bit images in the buffer are subtracted in real-time ESPI fringe patterns on the monitor, which can be correlated to the displacements in the crack tip region. The technique of ESPI has been implemented on solid propellant material. Work is currently in progress on the extraction of the displacement components and interpretation of the fracture behavior in terms of classical fracture mechanics of viscoelastic materials.

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Space Systems EMC/EMI Analysis using IEMCAP

Jeffrey T. Williams, Ph.D., Donald R. Wilton, and Noel Purcell; NASA coordinator, Dickie Arndt

Investigators initiated this study to determine the suitability of the Intrasystem Electromagnetic Compatibility Analysis Program (IEMCAP) for predicting and analyzing electromagnetic energy, coupling between devices within complex systems. Such tools as EIMCAP, developed by the Air Force, are needed in the aerospace industry to predict electromagnetic compatibility (EMC) and electromagnetic interference (EMI) between electronic subsystems scheduled for installation in a close environment like a space station. Coupling mechanisms chosen for study in this project included wire-to-wire and case-to-case coupling.

Detailed calculations and experiments showed the IEMCAP is a good predictor of upper bounds for wire-to-wire coupling at low frequencies. Results indicated that IEMCAP is not a reliable predictor of wire-to-wire coupling at high frequencies, however, due, apparently, to failure of its simple model at the frequencies.

The IEMCAP model for case-to-case modeling as found to be inadequate over a wide range of frequencies. IEMCAP essentially assumes a dipole model for equipment case radiation, with a constant determined by near field measurement at one field point. The research was summarized in a report to NASA entitled "Space Systems EMC/EMI Analysis Using IEMCAP," with Noel Purcell, Jeffrey T. Williams, and Donald R. Wilton credited as authors of the work.

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Development of Integrated Circuit Packaging Techniques for Curved Surfaces

John C. Wolfe, Ph.D., Department of Electrical and Computer Engineering

ISSO investigators sought to develop a competitive proposal for a target-acquisition radar (Seeker). A team was formed with Science Applications International Corp. (SAIC) and Hughes Research Laboratory whereby design and testing was to be performed at SAIC, Hughes would provide transmitter chips, and ISSO researchers would fabricate the actual radar. Proof-of-concepts experiments were carried out and incorporated in the proposal, which was submitted for review to the Army Strategic Defense Command.

The fabrication process comprised the following design goals: Lithographic resolution = 10-4d, where d is the depth of field Maximum depth-of-field = 1 cm Linewidth tolerance = 5 mm Edge slope of etched structures = < 5&degree; Etch depth = 0-100 mm Structural material = Al or Si, TBD by University of Houston Electrical conductor = Al, Au, or Ag, TBD by mutual agreement Dielectric = polymide

The monolithic seeker is being designed as an array of 5500 transmit/receive (T/R) modules mounted vertically through an aluminum substrate (Fig. 1). These modules are driven by an integrated waveguide feed structure on one side of the substrate. An interconnect network containing dc-bias and transmit/receive control lines is defined on the other. The network is covered by the antenna ground plane and a diamond window. The T/R modules are embedded in the substrate. The waveguide is filled with polymide to reduce its size and provide rigidity for the electric field probe. In addition, the bonding of the T/R modules to the interconnect network is conformal, requiring no bond wires. The result should be a robust package weighing less than one hundred grams, which is amenable to high throughput packaging techniques. The design of the structure is expected to evolve during the design phase, but the basic structure serves as a model for developing an approach to manufacturing.

The University of Houston has experience in lithography and processing. The advanced lithography program was established five years ago at the University to address problems of 3-dimensional integration in automotive electronics.


Contents
ISSO -- Institute for Space Systems Operations
1992-1993 Annual Report

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