System Health Management - With Aerospace Applications

System Health Management: with Aerospace Applications provides the first complete reference text for System Health Management (SHM), the set of technologies and processes used to improve system dependability. Edited by a team of engineers and consultants with SHM design, development, and research experience from NASA, industry, and academia, each heading up sections in their own areas of expertise and co-coordinating contributions from leading experts, the book collates together in one text the state-of-the-art in SHM research, technology, and applications. It has been written primarily as a reference text for practitioners, for those in related disciplines, and for graduate students in aerospace or systems engineering.

There are many technologies involved in SHM and no single person can be an expert in all aspects of the discipline.System Health Management: with Aerospace Applications provides an introduction to the major technologies, issues, and references in these disparate but related SHM areas. Since SHM has evolved most rapidly in aerospace, the various applications described in this book are taken primarily from the aerospace industry. However, the theories, techniques, and technologies discussed are applicable to many engineering disciplines and application areas.

Readers will find sections on the basic theories and concepts of SHM, how it is applied in the system life cycle (architecture, design, verification and validation, etc.), the most important methods used (reliability, quality assurance, diagnostics, prognostics, etc.), and how SHM is applied in operations (commercial aircraft, launch operations, logistics, etc.), to subsystems (electrical power, structures, flight controls, etc.) and to system applications (robotic spacecraft, tactical missiles, rotorcraft, etc.).

Dr Stephen B. Johnson is a Heath Management Systems Engineer at the NASA Marshall Space Flight Center in the USA, as well as an associate research professor at the University of Colorado at Colorado Springs. He has been active in the field of SHM for over 20 years, and has authored many research papers on the topic. He has also authored or edited 3 books in the aerospace field including The Secret of Apollo: Systems Management in American and European Space Programs.

Mr Thomas Gormley has been involved with the NASA Aerospace industry for over 20 years, and was the Integrated Vehicle Health Management Project Leader for Rockwell Space Systems during the early 1990s. He brings expertise in systems implementation to the project.

Dr Seth S. Kessler is president and owner of Metis Design Corporation, a design consulting firm specializing in custom sensing solutions. He brings expertise in structural health monitoring and composite materials to the project.

Mr Charles Mott is a business analyst with the Tauri group, currently under contract at NASA. He brings expertise in the socio-technical aspects of large-scale technological projects to the project.

Dr Ann Patterson-Hine is Group Leader of the Health Management Technologies Group at the Ames Research Center. She brings expertise on the use of engineering models for model-based reasoning in advanced monitoring and diagnostic systems to the project.

Dr Karl Reichard is head of the ARL Penn State Monitoring and Automation Department. He brings expertise in the implementation of signal processing, control and embedded diagnost

Mr Philip A. Scandura, Jr joined Honeywell in 1984 where he currently holds the position of Staff Scientist in their Advanced Technology Organization. He brings expertise in the system definition and implementation of real-time, embedded systems for use in safety-critical and mission-critical applications to the project.

About the Editors
List of Contributors
Foreword
Series Editor Preface
Preface
Acronyms

Part One The Socio-technical Context of System Health Management
Charles D. Mott

1 The Theory of System Health Management
Stephen B. Johnson
Overview
1.1 Introduction
1.2 Functions, Off-Nominal States, and Causation
1.3 Complexity and Knowledge Limitations
1.4 SHM Mitigation Strategies
1.5 Operational Fault Management Functions
1.6 Mechanisms
1.7 Summary of Principles
1.8 SHM Implementation
1.9 Some Implications
1.10 Conclusion
Bibliography

2 Multimodal Communication
Beverly A. Sauer
Overview
2.1 Multimodal Communication in SHM
2.2 Communication Channels
2.3 Learning from Disaster
2.4 Current Communication in the Aerospace Industry
2.5 The Problem of Sense-making in SHM Communication
2.6 The Costs of Faulty Communication
2.7 Implications
2.8 Conclusion
Acknowledgments
Bibliography

3 Highly Reliable Organizations
Andrew Wiedlea
Overview
3.1 The Study of HROs and Design for Dependability
3.2 Lessons from the Field: HRO Patterns of Behavior
3.3 Dependable Design, Organizational Behavior, and Connections to the HRO Project
Bibliography

4 Knowledge Management
Edward W. Rogers
Overview
4.1 Systems as Embedded Knowledge
4.2 KM and Information Technology
4.3 Reliability and Sustainability of Organizational Systems
4.4 Case Study of Building a Learning Organization: Goddard Space Flight Center
4.5 Conclusion
Bibliography

5 The Business Case for SHM
Kirby Keller and James Poblete
Overview
5.1 Business Case Processes and Tools
5.2 Metrics to Support the Decision Process
5.3 Factors to Consider in Developing an Enterprise Model
5.4 Evaluation of Alternatives
5.5 Modifications in Selected Baseline Model
5.6 Modeling Risk and Uncertainty
5.7 Model Verification and Validation
5.8 Evaluation Results
5.9 Summary and Conclusions
Bibliography

Part Two SHM and the System Lifecycle
Seth S. Kessler

6 Health Management Systems Engineering and Integration
Timothy J. Wilmering and Charles D. Mott
Overview
6.1 Introduction
6.2 Systems Thinking
6.3 Knowledge Management
6.4 Systems Engineering
6.5 Systems Engineering Lifecycle Stages
6.6 Systems Engineering, Dependability, and Health Management
6.7 SHM Lifecycle Stages
6.8 SHM Analysis Models and Tools
6.9 Summary
Acknowledgments
Bibliography

7 Architecture
Ryan W. Deal and Seth S. Kessler
Overview
7.1 Introduction
7.2 SHM System Architecture Components
7.3 Examples of Power and Data Considerations
7.4 SHM System Architecture Characteristics
7.5 SHM System Architecture Advanced Concepts
7.6 Summary
Bibliography

8 System Design and Analysis Methods
Irem Y. Tumer
Overview
8.1 Introduction
8.2 Lifecycle Considerations
8.3 Design Methods and Practices for Effective SHM
8.4 Summary
Acknowledgments
Bibliography

9 Assessing and Maturing Technology Readiness Levels
Ryan M. Mackey
Overview
9.1 Introduction
9.2 Motivating Maturity Assessment
9.3 Review of Technology Readiness Levels
9.4 Special Needs of SHM
9.5 Mitigation Approaches
9.6 TRLs for SHM
9.7 A Sample Maturation Effort
9.8 Summary
Bibliography

10 Verification and Validation
Lawrence Z. Markosian, Martin S. Feather, and David E. Brinza
Overview
10.1 Introduction
10.2 Existing Software V&V
10.3 Feasibility and Sufficiency of Existing Software V&V Practices for SHM
10.4 Opportunities for Emerging V&V Techniques Suited to SHM
10.5 V&V Considerations for SHM Sensors and Avionics
10.6 V&V Planning for a Specific SHM Application
10.7 A Systems Engineering Perspective on V&V of SHM
10.8 Summary
Acknowledgments
Bibliography

11 Certifying Vehicle Health Monitoring Systems
Seth S. Kessler, Tom Brotherton, and Grant A. Gordon
Overview
11.1 Introduction
11.2 Durability for VHM Systems
11.3 Mechanical Design for Structural Health Monitoring Systems
11.4 Reliability and Longevity of VHM Systems
11.5 Software and Hardware Certification
11.6 Airworthiness Certification
11.7 Health and Usage Monitoring System Certification Example
11.8 Summary
Acknowledgments
Bibliography

Part Three Analytical Methods
Ann Patterson-Hine

12 Physics of Failure
Kumar V. Jata and Triplicane A. Parthasarathy
Overview
12.1 Introduction
12.2 Physics of Failure of Metals
12.3 Physics of Failure of CMCs
12.4 Summary
Bibliography

13 Failure Assessment
Robyn Lutz and Allen Nikora
Overview
13.1 Introduction
13.2 FMEA
13.3 SFMEA
13.4 FTA
13.5 SFTA
13.6 BDSA
13.7 Safety Analysis
13.8 Software Reliability Engineering
13.9 Tools and Automation
13.10 Future Directions
13.11 Conclusion
Acknowledgments
Bibliography

14 Reliability
William Q. Meeker and Luis A. Escobar
Overview
14.1 Time-to-Failure Model Concepts and Two Useful Distributions
14.2 Introduction to System Reliability
14.3 Analysis of Censored Life Data
14.4 Accelerated Life Testing
14.5 Analysis of Degradation Data
14.6 Analysis of Recurrence Data
14.7 Software for Statistical Analysis of Reliability Data
Acknowledgments
Bibliography

15 Probabilistic Risk Assessment
William E. Vesely
Overview
15.1 Introduction
15.2 The Space Shuttle PRA
15.3 Assessing Cumulative Risks to Assist Project Risk Management
15.4 Quantification of Software Reliability
15.5 Description of the Techniques Used in the Space Shuttle PRA
15.6 Conclusion
Bibliography

16 Diagnosis
Ann Patterson-Hine, Gordon Aaseng, Gautam Biswas, Sriram Narasimhan, and Krishna Pattipati
Overview
16.1 Introduction
16.2 General Diagnosis Problem
16.3 Failure Effect Propagation and Impact
16.4 Testability Analysis
16.5 Diagnosis Techniques
16.6 Automation Considerations for Diagnostic Systems
16.7 Conclusion
Acknowledgments
Bibliography

17 Prognostics
Michael J. Roemer, Carl S. Byington, Gregory J. Kacprzynski, George Vachtsevanos, and Kai Goebel
Overview
17.1 Background
17.2 Prognostic Algorithm Approaches
17.3 Prognosis RUL Probability Density Function
17.4 Adaptive Prognosis
17.5 Performance Metrics
17.6 Distributed Prognosis System Architecture
17.7 Conclusions
Bibliography

Part Four Operation
Karl M. Reichard

18 Quality Assurance
Brian K. Hughitt
Overview
18.1 NASA QA Policy Requirements
18.2 Quality System Criteria
18.3 Quality Clauses
18.4 Workmanship Standards
18.5 Government Contract Quality Assurance
18.6 Government Mandatory Inspection Points
18.7 Quality System Audit
18.8 Conclusions
Bibliography

19 Maintainability: Theory and Practice
Gary O'Neill
Overview
19.1 Definitions of Reliability and Maintainability
19.2 Reliability and Maintainability Engineering
19.3 The Practice of Maintainability
19.4 Improving R&M Measures
19.5 Conclusions
Bibliography

20 Human Factors
Robert S. McCann and Lilly Spirkovska
Overview
20.1 Background
20.2 Fault Management on Next-Generation Spacecraft
20.3 Integrated Fault Management Automation Today
20.4 Human-Automation Teaming for Real-Time FM
20.5 Operations Concepts for Crew-Automation Teaming
20.6 Empirical Testing and Evaluation
20.7 Future Steps
20.8 Conclusions
Bibliography

21 Launch Operations
Robert D. Waterman, Patricia E. Nicoli, Alan J. Zide, Susan J. Waterman, Jose M. Perotti, Bob A. Ferrell, and Barbara L. Brown
Overview
21.1 Introduction to Launch Site Operations
21.2 Human-Centered Health Management
21.3 SHM
21.4 LS Abort and Emergency Egress
21.5 Future Trends Post Space Shuttle
21.6 Summary
Bibliography

22 Fault Management Techniques in Human Spaceflight Operations
Brian O'Hagan and Alan Crocker
Overview
22.1 The Flight Operations Team
22.2 System Architecture Implications
22.3 Operations Products, Processes, and Techniques
22.4 Lessons Learned from Space Shuttle and ISS Experience
22.5 Conclusions
Bibliography

23 Military Logistics
Eddie C. Crow and Karl M. Reichard
Overview
23.1 Focused Logistics
23.2 USMC AL
23.3 Benefits and Impact of SHM on Military Operations and Logistics
23.4 Demonstrating the Value of SHM in Military Operations and Logistics
23.5 Conclusion
Bibliography

Part Five Subsystem Health Management
Philip A. Scandura, Jr.

24 Aircraft Propulsion Health Management
Al Volponi and Bruce Wood
Overview
24.1 Introduction
24.2 Basic Principles
24.3 Engine-Hosted Health Management
24.4 Operating Conditions
24.5 Computing Host
24.6 Software
24.7 On-Board Models
24.8 Component Life Usage Estimation
24.9 Design of an Engine Health Management System
24.10 Supporting a Layered Approach
24.11 Conclusion
Bibliography

25 Intelligent Sensors for Health Management
Gary Hunter, Lawrence Oberle, George Baaklini, Jose Perotti, and Todd Hong
Overview
25.1 Introduction
25.2 Sensor Technology Approaches
25.3 Sensor System Development
25.4 Supporting Technologies: High-Temperature Applications Example
25.5 Test Instrumentation and Non-destructive Evaluation (NDE)
25.6 Transition of Sensor Systems to Flight
25.7 Supporting a Layered Approach
25.8 Future Directions
Acknowledgments
Bibliography

26 Structural Health Monitoring
Fu-Kuo Chang, Johannes F.C. Markmiller, Jinkyu Yang, and Yujun Kim
Overview
26.1 Introduction
26.2 Proposed Framework
26.3 Supporting a Layered Approach
26.4 Conclusion
Acknowledgments
Bibliography

27 Electrical Power Health Management
Robert M. Button and Amy Chicatelli
Overview
27.1 Introduction
27.2 Summary of Major EPS Components and their Failure Modes
27.3 Review of Current Power System HM
27.4 Future Power SHM
27.5 Supporting a Layered Approach
27.6 Conclusion
Bibliography

28 Avionics Health Management
Michael D. Watson, Kosta Varnavas, Clint Patrick, Ron Hodge, Carl S. Byington, Savio Chau and Edmund C. Baroth
Overview
28.1 Avionics Description
28.2 Electrical, Electronic, and Electromechanical (EEE) Parts Qualification
28.3 Environments
28.4 Failure Sources
28.5 Current Avionics Health Management Techniques
28.6 Avionics Health Management Requirements
28.7 Supporting a Layered Approach
28.8 Summary
Bibliography

29 Failure-Tolerant Architectures for Health Management
Daniel P. Siewiorek and Priya Narasimhan
Overview
29.1 Introduction
29.2 System Failure Response Stages
29.3 System-Level Approaches to Reliability
29.4 Failure-Tolerant Software Architectures for Space Missions
29.5 Failure-Tolerant Software Architectures for Commercial Aviation Systems
29.6 Observations and Trends
29.7 Supporting a Layered Approach
29.8 Conclusions
Acknowledgments
Bibliography

30 Flight Control Health Management
Douglas Zimpfer
Overview
30.1 A FC Perspective on System Health Management
30.2 Elements of the FC System
30.3 FC Sensor and Actuator HM
30.4 FC/Flight Dynamics HM
30.5 FC HM Benefits
30.6 Supporting a Layered Approach
30.7 Summary
Bibliography

31 Life Support Health Management
David Kortenkamp, Gautam Biswas, and Eric-Jan Manders
Overview
31.1 Introduction
31.2 Modeling
31.3 System Architecture
31.4 Future NASA Life Support Applications
31.5 Supporting a Layered Approach
31.6 Conclusions
Bibliography

32 Software
Philip A. Scandura, Jr.
Overview
32.1 Sampling of Accidents Attributed to Software Failures
32.2 Current Practice
32.3 Challenges
32.4 Supporting a Layered Approach
32.5 Summary
Bibliography

Part Six System Applications
Thomas J. Gormley

33 Launch Vehicle Health Management
Edward N. Brown, Anthony R. Kelley, and Thomas J. Gormley
Overview
33.1 Introduction and Definition
33.2 LVSHM Functionality and Scope
33.3 LV Terminology and Operations
33.4 LV Reliability Lessons Learned
33.5 LV Segment Requirements and Architecture
33.6 LVSHM Analysis and Design
33.7 LV LVSHM System Descriptions
33.8 LVSHM Future System Requirements
33.9 Conclusion
Bibliography

34 Robotic Spacecraft Health Management
Paula S. Morgan
Overview
34.1 Robotic Spacecraft SHM: Introduction
34.2 Spacecraft Health and Integrity Concerns for Deep-Space Missions
34.3 Spacecraft SHM Implementation Approaches
34.4 Standard FP Implementation
34.5 Robotic Spacecraft SHM Allocations
34.6 Spacecraft SHM Ground Rules and Requirements
34.7 SFP and SIFP Architectures
34.8 Example of Standard FP Application: Under-voltage Trip
34.9 Robotic Spacecraft SHM: Conclusion
Bibliography

35 Tactical Missile Health Management
Abdul J. Kudiya and Stephen A. Marotta
Overview
35.1 Introduction
35.2 Stockpile Surveillance Findings
35.3 Probabilistic Prognostics Modeling
35.4 Conclusion
Bibliography

36 Strategic Missile Health Management
Gregory Ruderman
Overview
36.1 Introduction
36.2 Fundamentals of Solid Rocket Motors
36.3 Motor Components
36.4 Challenges for Strategic Rocket Health Management
36.5 State of the Art for Solid Rocket Systems Health Management (SHM)
36.6 Current Challenges facing SRM SHM
36.7 Conclusion: A Way Forward
Bibliography

37 Rotorcraft
Paula J. Dempsey and James J. Zakrajsek
Overview
37.1 Introduction
37.2 Rotorcraft SHM Standard Practices
37.3 New Practices
37.4 Lessons Learned
37.5 Future Challenges
37.6 Conclusion
Bibliography

38 Commercial Aviation Health Management
Philip A. Scandura, Jr., Michael Christensen, Daniel Lutz, and Gary Bird
Overview
38.1 Commercial Aviation Challenge
38.2 Layered Approach to SHM
38.3 Evolution of Commercial Aviation SHM
38.4 Commercial State of the Art
38.5 The Next Generation: Intelligent Vehicles/Sense & Respond
38.6 Moving Beyond Maintenance
Bibliography

Glossary
Index