Dr. Krishna R. Pattipati, Dr. Somnath Deb, Dr. Sudipto Ghoshal

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Supportability Engineering Intelligent
Integrated Health- Management for NASA
Exploration Systems
Dr. Krishna R. Pattipati, Dr. Somnath Deb, Dr.
Sudipto Ghoshal Qualtech Systems,
Inc. Wethersfield, CT E-mail krishna_at_teamqsi.com
Tel./Fax [phone] Dr. Ann
Patterson-Hine, NASA-ARC
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Qualtech Systems Inc.
Customers

• Company
• Integrated Diagnostics Solutions
• Design for Supportability
• Embedded Diagnostics
• Guided Support Operations
• COTS Components and Customizations

• Credentials
• NASA Space Act Award
• Aviation Week Award
• Connecticut Fast 50 2001-2005
• 2006 Harry T. Jensen Award

• Applications of Integrated Diagnostic Solutions
  to NASA DOD Programs
• NASA ? RLV, CEV, Wire Integrity Program
• DoD ? F135, F119, T700, JAHUMS, ATEDS

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Supportability Analysis
Acquisition Costs
Development Cost (Research, Design,
Test, Production, Construction)
Operations Cost (Personnel, Facilities, Utilities,
and Energy)
A Program focusing on Product Inherent Design
only during the Development phases
Product Distribution Cost (Transportation,
Traffic, And Material Handling)
Supportability ConsidersTotal System Cost of
Ownership
Software Cost (Operating and Maintenance Software)
Maintenance Cost (Customer Service, Field,
Supplier Factory, Maintenance)
Test and Support Equipment Cost
Approximately 70 of a project's life cycle
costs (LCC) are determined at the concept phase
Training Cost (Operator and Maintenance Training)
Technical Data Cost
Supply Support Cost (Spares, Inventory, And
Material Support)
Operations and Support Costs
The largest percentage of System ownership costs
are associated with Operations and Support.
These costs are often overlooked during the
development phase, where focus is often on the
cost of acquisition only.
Retirement and Disposal Cost
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The Concept
Provide a powerful tool set that is value added
to current analysis tools and capabilities

• Provide an intuitive, graphical modeling tool
  that allows system design characteristics to be
  captured and refined from early concept through
  operations over the course of the entire life
  cycle
• Provide a tool to help evaluate, optimize and
  design out risk, safety issues, mission
  reliability issues, and reduce maintenance times
  and life-cycle support costs
• Provide advanced capabilities to automate PRA,
  FTA, FMECA, testability analysis, safety
  assessments
• Provide additional tools that take the results
  of these models and analysis and directly
  IMPLEMENT them in the ISHM (On/Off Board)
  solution A seamless process from Analysis to
  Implementation!

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Integrated Health Management Process
Integrated Tools
Allows for model re-use across all phases of
system life-cycle concept, design, development,
production, operations, and training Use of
the same model ensures that the results predicted
by testability analysis are achievable and
repeatable in operations
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RMT Analysis Using TEAMS
Testability Analysis
Domain Knowledge

• TFOMs, undetected faults, Ambiguity Groups
• Timing Requirements

Legacy Data
Field Data
Vehicle Health Determination
Engineering Simulation Data

• Failure Modes
• Functional Failures
• Functional Failure Mappings
• Failure Effects, Tests, Error Codes
• Cause-effect dependencies
• System Modes, Configurations
• Redundancies and Fault Tolerance
• Parameters (Failure Rates, costs etc)
• Severity Class

Ground Support

• Existing FMECA
• FRACAS reports, etc.

Conventional fault tree with colored nodes
indicating severity category
Minimal combinations of events leading to system
failure and their probabilities
List of Minimal Cut Sets
Reliability Analysis Reports
Measures of Importance Reports
Fault Tree
FMECA Report
System reliability vs. time up to the end of the
mission duration
Importance of each initiating event/failure mode
FMECA report with diagnostic tree for each
functional failure
FTA, PRA and Reliability Analysis
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Analysis Drives the Implementation

• Critical effects determine the critical faults,
  and reliability analysis generates probabilities
  for those effects
• Timing analysis determines the time to effect and
  detect and the margin for corrective action
• FMECA analysis determines the effects/functions
  tied to critical failures and their mitigation
  procedures
• All the above information can be utilized to
  design onboard diagnostic tests to ensure mission
  safety and reliability
• A O procedures can be layered in for design
  evaluation tied to mission safety/reliability/diag
  nosability
• All the analyses are concurrent with the design
  updates
• With a single source for change incorporation
  (the model), FMECA and other analysis reports are
  living documents that evolve with the design and
  drive the implementation

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Modeling, Analysis FMECA Life-Cycle Process
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Deployment Scenarios

• Amenable to a variety of Architecture scenarios
• Onboard, Online, embedded (e.g., HUMS, JSF)
• Offboard, Online, telediagnosis (e.g., ISS)
• Onboard, Online, Networked (e.g., Microserver)
• Offboard, Offline playback (e.g., Apache
  helicopters)
• Separation of tests from root-cause allow
  flexible solutions

Corrective Actions (Impact Assmt, Cautions/Warning
, Procedures, Maintenance, Logistics)
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Real-Time Engine Health Assessment

• Solution
• TEAMS-RT embedded in F-135 engine
  controller for real-time fault isolation
• Results validated in over 12,000 test cases

• Challenge
• Supportable, affordable fleet operation

• Benefit
• Ground support is as simple as swapping LRCs
• Reduced logistics footprint due to reduced false
  pulls, and requirement for ground support
  equipment and technician skill level

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Case Study Honeywell
JOHNSON SPACE CENTER

• Solution
• TEAMS-RDS monitoring ISS telemetry data at JSc

• Challenge
• Help ISS Mission Controllers cope with their
  workload

• Benefit
• Early detection and mitigation of problems
  (before system failure)
• Automatic cross-discipline fault isolation
• Dashboard for continuous health awareness

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Benefits

• Provides ease of design capture
• Provides a common graphical representation of the
  vehicle, system, sub-system, to the component
  level
• Integrates with existing engineering, safety,
  maintenance and logistical data bases
• Allows detailed design trade studies to determine
  optimal implementation of embedded diagnostics,
  fault tolerance, maintenance strategy
  (on-board/off-board), and logistical support
• Automates a number of analysis functions, thus
• Reduces engineering work load
• Provides insight into design decisions
• Reduces conflicts, errors and omissions
• Provides cost and effectiveness measures as the
  design evolves and throughout its lifecycle
• Seamless transition of diagnostic reasoners into
  the ISHM/IVHM (On Board/Off Board) solution
  ensures that fault detection, fault isolation,
  and failure mitigation perform as advertised