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
ISS | Space Exploration
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
Thermal-StructuralLoads Analysis
Telemetry AnalysisBuild PaperReview
Build PaperReview
Fault TreeAnalysis
Fault TreeAnalysis
Witness CouponMetallography
Tribological Material Testing
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
ISS | Space Exploration
Roller Contact Area Decreases for Increasing Thrust Load
TBA Roller Edge Loading
Contact Area Mean Contact Pressure
ISS | Space Exploration
Contact Stress Peaking Caused By Roller Profile Geometry
Root Cause - Other Contributors
Discontinuous Intergranular Separations (DIGS)
DIGS
Intergranular Networking
White Layer
Inclusion
ISS | Space Exploration
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 Test24Q'08
Post Lube Test31Q'09
Post Lube Tets42Q'09
Post Lube Test53Q'09
(g)
Avg. Maximum g
0
.5
1.0
Dri
ve M
oto
r C
urre
nt (
Am
ps)
Cleaning and Lubrication Task
ISS | Space Exploration
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
ISS | Space Exploration
Supporting Material
ISS | Space ExplorationStarboard SARJ
ISS | Space ExplorationSARJ, Covers Removed
Bearing Race
Trundle Bearing Assembly x12
ISS | Space Exploration
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
High FrictionalThrust Loads
Roller BearingEdge Loading
High StressesIn Nitride Case
Race RingSurface Spalling
Gold Delamination Roller
Mistracking
Roller ProfileGeometry
DIGS
Lubricant SystemUnderperforms
High FrictionalThrust Loads
Roller BearingEdge Loading
High StressesIn Nitride Case
Race RingSurface Spalling
Gold Delamination Roller
Mistracking
Roller ProfileGeometry
DIGS
ISS | Space ExplorationEVA Cleaning Tools
Scraper Tool Grease Gun w/ J-Hook Nozzle
EVA Wipe Grease Gun w/ Straight Nozzle
ISS | Space Exploration
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 Test24Q'08
Post Lube Test31Q'09
Post Lube Tets42Q'09
Post Lube Test53Q'09
(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
ISS | Space Exploration
EWIS / SDMS Sensor Location Overview
- External Wireless Instrumentation System (EWIS): 10 triaxial accels
- Structural Dynamics Measurement System (SDMS): 33 accel channels
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 Test24Q'08
Post Lube Test31Q'09
Post Lube Tets42Q'09
Post Lube Test53Q'09
(g)
Avg. Maximum g
ISS | Space ExplorationRoot Cause Investigation
LM RollerCoupon Test
LM RollerCoupon Test
GRC Rolling TractionTestGRC Rolling TractionTest
TBA Inspection& Metrology
TBA Inspection& Metrology
DebrisMicrography
DebrisMicrography
Multi-BodyDynamics Simulation
Multi-BodyDynamics Simulation
Thermal-StructuralLoads Analysis
Thermal-StructuralLoads Analysis
Telemetry AnalysisTelemetry AnalysisBuild PaperReview
Build PaperReview
Fault TreeAnalysis
Fault TreeAnalysis
Witness CouponMetallography
Witness CouponMetallography
Tribological Material Testing
Tribological Material Testing
Tests and Inspections Analyses
Root CauseRoot Cause
Stress and Rolling Mechanics AnalysesStress and Rolling
Mechanics Analyses
LM RollerCoupon Test
LM RollerCoupon Test
GRC Rolling TractionTestGRC Rolling TractionTest
TBA Inspection& Metrology
TBA Inspection& Metrology
DebrisMicrography
DebrisMicrography
Multi-BodyDynamics Simulation
Multi-BodyDynamics Simulation
Thermal-StructuralLoads Analysis
Thermal-StructuralLoads Analysis
Telemetry AnalysisTelemetry AnalysisBuild PaperReview
Build PaperReview
Fault TreeAnalysis
Fault TreeAnalysis
Witness CouponMetallography
Witness CouponMetallography
Tribological Material Testing
Tribological Material Testing
Tests and Inspections Analyses
Root CauseRoot Cause
Stress and Rolling Mechanics AnalysesStress and Rolling
Mechanics Analyses
ISS | Space Exploration
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
LM RollerCoupon Test
LM RollerCoupon Test
GRC Rolling TractionTestGRC Rolling TractionTest
TBA Inspection& Metrology
TBA Inspection& Metrology
DebrisMicrography
DebrisMicrography
Multi-BodyDynamics Simulation
Multi-BodyDynamics Simulation
Thermal-StructuralLoads Analysis
Thermal-StructuralLoads Analysis
Telemetry AnalysisTelemetry AnalysisBuild PaperReview
Build PaperReview
Fault TreeAnalysis
Fault TreeAnalysis
Witness CouponMetallography
Witness CouponMetallography
Tribological Material Testing
Tribological Material Testing
Tests and Inspections Analyses
Root CauseRoot Cause
Stress and Rolling Mechanics AnalysesStress and Rolling
Mechanics Analyses
LM RollerCoupon Test
LM RollerCoupon Test
GRC Rolling TractionTestGRC Rolling TractionTest
TBA Inspection& Metrology
TBA Inspection& Metrology
DebrisMicrography
DebrisMicrography
Multi-BodyDynamics Simulation
Multi-BodyDynamics Simulation
Thermal-StructuralLoads Analysis
Thermal-StructuralLoads Analysis
Telemetry AnalysisTelemetry AnalysisBuild PaperReview
Build PaperReview
Fault TreeAnalysis
Fault TreeAnalysis
Witness CouponMetallography
Witness CouponMetallography
Tribological Material Testing
Tribological Material Testing
Tests and Inspections Analyses
Root CauseRoot Cause
Stress and Rolling Mechanics AnalysesStress and Rolling
Mechanics Analyses
ISS | Space ExplorationRoot Cause Investigation
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
ISS | Space Exploration
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
ISS | Space ExplorationRoot Cause Investigation
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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