Sweeney.dan

NASA Project Management Challenge 2011

The International Space Station Solar Alpha Rotary Joint Anomaly Investigation

The Boeing Company – Houston, TXElliot Harik, Justin McFatter, Carlos Enriquez

and David McCann

NASA - Johnson Space CenterDaniel Sweeney and Deneen Taylor

ISS | Space Exploration

International Space Station Overview

Solar Alpha Rotary Joint with a Focus on Relevant Components

Anomaly Onset and On-Orbit Investigation

Anomaly Root Cause Investigation

Detailed Review of Roller Bearing Edge Loading and Associated Stress Profiles

Development and Implementation of a Corrective Action

Closing Remarks

Discussion Overview

ISS | Space ExplorationInternational Space Station Overview

ISS | Space ExplorationSolar Alpha Rotary Joint Overview

SARJ

ISS | Space ExplorationAnomaly Onset and On-Orbit Investigation

ISS | Space ExplorationAnomaly Onset and On-Orbit Investigation


Limited Functionality to Critical System Reduction to Power Generation Astronaut Training and Time Shift to ISS Mission Priorities Hardware Development Cost Array Positioning Flexibility Constricted

– Dynamic Loads– ISS Drag and Altitude Reboost– Contamination– “Longeron Shadowing”

Space Shuttle Manifest Planning Complicated Significant Logistics and Maintenance Effort

Impact of Anomaly to ISS Program

ISS | Space ExplorationRoot Cause Investigation

LM RollerCoupon Test

GRC Rolling TractionTest

TBA Inspection& Metrology

DebrisMicrography

Multi-BodyDynamics Simulation

Thermal-StructuralLoads Analysis


Telemetry AnalysisBuild PaperReview

Build PaperReview

Fault TreeAnalysis

Fault TreeAnalysis

Witness CouponMetallography

Tribological Material Testing


Tests and Inspections Analyses

Root Cause

Stress and Rolling Mechanics Analyses

ISS | Space ExplorationRoot Cause Summary

NF *

N

Pw

hNF *

N

Pw

Pw

h

Lubricant SystemUnderperforms

High FrictionalThrust Loads

Roller BearingEdge Loading

High StressesIn Nitride Case

Race RingSurface Spalling

Gold Delamination Roller

Mistracking

Roller ProfileGeometry

DIGS

ISS | Space ExplorationTBA Roller Stability and Edge Loading

CamberAxis

N

F

N

F

N

Pure NormalContact

Stable CamberTilt

Unstable CamberTilt (Tipping)

dd

d is the lateral distance to the center of pressure of the contact In stable tilting, d increases with increasing camber angle In unstable tilting, d decreases with increasing camber angle Investigation shows that SARJ TBA rollers remained stable during anomaly


Roller Contact Area Decreases for Increasing Thrust Load

TBA Roller Edge Loading

Contact Area Mean Contact Pressure


Contact Stress Peaking Caused By Roller Profile Geometry

Root Cause - Other Contributors

Discontinuous Intergranular Separations (DIGS)

DIGS

Intergranular Networking

White Layer

Inclusion


Do Nothing – Continue to impact operations and operate for life of ISS with degraded power generation capability. No risk from configuration change or unplanned maintenance activity.

SARJ XL – Alter ISS system physical configuration. Add additional bearing race, causing the truss to be extended out several inches (i.e. XL). If successful the impact of the anomaly to forward operation would be negligible. Significant risk to implement.

SARJ FR – Expand existing SARJ level system architecture to allow for fully redundant (FR) contingency mode of operation.

Replace TBAs, Clean and Lubricate Bearing Faces – Replace bearing components and add grease lubricant to the system in the hope to ameliorate some of the more significant impacts of the anomaly. Intent is to extend operation in degraded mode until more permanent solution available.

Corrective Action Options

Initial plan to pursue SARJ XL along with cleaning and lubrication

ISS | Space ExplorationAnomaly Corrective Action

ISS | Space ExplorationAnomaly Corrective Action

SSARJ Rotation, S3 Average Maximum Amplitude vs Event

0.0003

0.0124

0.0172

0.0141

0.0016 0.0013 0.0017 0.0014 0.0015

0

0.002

0.004

0.006

0.008

0.01

0.012

0.014

0.016

0.018

Pre-Anomoly 3Q'07

Anomoly Detected4Q'07

SARJ DP 4Q'07-1Q'08

Slow DP 2Q-4Q'08

Post Lube Test14Q'08



Post Lube Tets42Q'09


(g)

Avg. Maximum g

0

.5

1.0

Dri

ve M

oto

r C

urre

nt (

Am

ps)

Cleaning and Lubrication Task


What Did We Learn?

Mechanism Design and Verification– Acceptance testing for complex mechanical systems should include run-in testing. This

period can be used to correlate analytical models of the system as well as provide a baseline for performance.

– Test correlated models should be used to identify sensitivities of the system and potential design issues

– An understanding of system sensitivities will allow for optimal use of instrumentation and monitoring techniques once the system has been deployed

– Mechanisms that operate in environments susceptible to debris contamination should consider inclusion of re-lubrication and cleaning capabilities

Diagnosing On-Orbit Anomalies– Operational data should be reviewed against previously baselined performance data (i.e.

running averages, percent changes), not system capabilities– Hands on inspection of the hardware, when feasible, should be undertaken ASAP after

anomaly detection

Closing Remarks

ISS | Space ExplorationAcknowledgements

40th Aerospace Mechanisms Symposium

The International Space Station Solar Alpha Rotary Joint Anomaly Investigation

The Boeing Company – Houston, TXElliot Harik, Justin McFatter, Carlos Enriquez

and David McCann

NASA - Johnson Space CenterDaniel Sweeney and Deneen Taylor


Supporting Material

ISS | Space ExplorationStarboard SARJ

ISS | Space ExplorationSARJ, Covers Removed

Bearing Race

Trundle Bearing Assembly x12


Bearing Race

Trundle Bearing Assembly

Gold Plated Rollers x3

ISS | Space ExplorationDrive/Lock Assembly

Drive Motor

Pinion

Bull Gear

ISS | Space ExplorationPressurized Elements

Columbus

JEM

US Lab

Node 2

ISS | Space ExplorationIon Plated Gold Delamination Lubricant SystemUnderperforms






Mistracking


DIGS

Lubricant SystemUnderperforms






Mistracking


DIGS

ISS | Space ExplorationEVA Cleaning Tools

Scraper Tool Grease Gun w/ J-Hook Nozzle

EVA Wipe Grease Gun w/ Straight Nozzle



0.0003

0.0124

0.0172

0.0141

0.0016 0.0013 0.0017 0.0014 0.0015

0

0.002

0.004

0.006

0.008

0.01

0.012

0.014

0.016

0.018

Pre-Anomoly 3Q'07


SARJ DP 4Q'07-1Q'08

Slow DP 2Q-4Q'08






(g)

Avg. Maximum g

Truss Accelerometer Data

Anomaly Post Cleaning and LubricatingPre-Anomaly

ISS | Space ExplorationStarboard SARJ Post Lube Avg Current

0.100

0.125

0.150

0.175

0.200

0 5 10 15 20 25 30 35

Days of Rotation

Dai

ly A

vera

ge C

urre

nt (

Am

ps) Starboard

Port

ISS | Space ExplorationPort SARJ, Pre and Post Lube Current

Pre-Lubrication Post-Lubrication

.100

.125

.150

Dri

ve M

oto

r C

urre

nt (

Am

ps)

November 2008

~30% Drop


EWIS / SDMS Sensor Location Overview

- External Wireless Instrumentation System (EWIS): 10 triaxial accels

- Structural Dynamics Measurement System (SDMS): 33 accel channels


0.0003

0.0124

0.0172

0.0141

0.0016 0.0013 0.0017 0.0014 0.0015

0

0.002

0.004

0.006

0.008

0.01

0.012

0.014

0.016

0.018

Pre-Anomoly 3Q'07


SARJ DP 4Q'07-1Q'08

Slow DP 2Q-4Q'08






(g)

Avg. Maximum g




GRC Rolling TractionTestGRC Rolling TractionTest



DebrisMicrography

DebrisMicrography





Telemetry AnalysisTelemetry AnalysisBuild PaperReview

Build PaperReview

Fault TreeAnalysis

Fault TreeAnalysis






Root CauseRoot Cause

Stress and Rolling Mechanics AnalysesStress and Rolling

Mechanics Analyses






DebrisMicrography

DebrisMicrography






Build PaperReview

Fault TreeAnalysis

Fault TreeAnalysis








Mechanics Analyses


0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.60

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Mistracking Angle (deg)

Thr

ust

Load

/ N

orm

al L

oad

TBA Free Camber Traction Curves

Datum A

Inner/Outer 45

Root Cause Integrated Analysis

Structural Models

Contact Stress

Multi-Body Dynamics

Thermal-Structural Loads Traction Kinematics






DebrisMicrography

DebrisMicrography






Build PaperReview

Fault TreeAnalysis

Fault TreeAnalysis








Mechanics Analyses






DebrisMicrography

DebrisMicrography






Build PaperReview

Fault TreeAnalysis

Fault TreeAnalysis








Mechanics Analyses


0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.60

0.1

0.2

0.3

0.4

0.5

0.6

0.7

Mistracking Angle (deg)

Thr

ust

Load

/ N

orm

al L

oad

TBA Free Camber Traction Curves

Datum A

Inner/Outer 45

Relationship between mistracking (toe) angle and thrust load was developed analytically and confirmed by test


SARJ Drive Motor Current

0.100

0.105

0.110

0.115

0.120

0.125

0.130

0.135

0.140

3/1/2010 4/1/2010 5/1/2010 6/1/2010 7/1/2010 8/1/2010 9/1/2010 10/1/2010 11/1/2010

Dai

ly A

vera

ge C

urre

nt

Port

Starboard

SARJ Performance Post Corrective Action

ISS | Space ExplorationSARJ XL Installation Demonstration

Astronaut

Robotic Arm

New Bearing Surface


111 FAILURE EVENTS IDENTIFIED397 ACTIONS ASSIGNED

SARJ ANOMALY FAULT TREE

A TEAM INCLUDING PARTNERS ACROSS NASA, INDUSTRY, AND ACADEMIA WAS FORMED TO

DETERMINE THE ROOT CAUSE.

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