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The paper considers results of test application of the reliability design and technological analysis (RDTA) for the nose fairing pusher of the aerial vehicle. The methodology procedures allow the designer to justify his decisions from the early stages of the life cycle making it possible to timely identify possible causes of the potential failures and take the necessary measures to eliminate or mitigate their consequences. The methodology is intended mainly to analyze the highly responsible unique products; however, it is not yet widely used in the rocket and space technology due to its novelty, and the regulatory framework is missing. To test the methodology, one of the mechanisms for the aerial vehicle one-time response was selected, i. e. the nose fairing pusher, which went through a full cycle of analytical and experimental verification according to the organization standards, and was approved for operation. Despite positive results of the pusher regular testing, the analysis revealed structural elements in it that required measures to improve reliability. An important result of the RDTA application was that the designers did not perceive results of the analysis as criticism, which is typical, for example, when using the FMEA procedures, but regarded them as an integral part of the design work. Despite the received specific recommendations to improve the pusher reliability, it turned out that the RDTA methodology needs further development and improvement for using by a wide range of designers and specialists, and it is also necessary to develop guidelines or standards for application in the standard organization developments.
The paper considers results of test application of the reliability design and technological analysis (RDTA) for the nose fairing pusher of the aerial vehicle. The methodology procedures allow the designer to justify his decisions from the early stages of the life cycle making it possible to timely identify possible causes of the potential failures and take the necessary measures to eliminate or mitigate their consequences. The methodology is intended mainly to analyze the highly responsible unique products; however, it is not yet widely used in the rocket and space technology due to its novelty, and the regulatory framework is missing. To test the methodology, one of the mechanisms for the aerial vehicle one-time response was selected, i. e. the nose fairing pusher, which went through a full cycle of analytical and experimental verification according to the organization standards, and was approved for operation. Despite positive results of the pusher regular testing, the analysis revealed structural elements in it that required measures to improve reliability. An important result of the RDTA application was that the designers did not perceive results of the analysis as criticism, which is typical, for example, when using the FMEA procedures, but regarded them as an integral part of the design work. Despite the received specific recommendations to improve the pusher reliability, it turned out that the RDTA methodology needs further development and improvement for using by a wide range of designers and specialists, and it is also necessary to develop guidelines or standards for application in the standard organization developments.
The paper examines the matters of operational dependability of space systems (SS), efficiency of complex systems, use of redundancy in spacecraft (SC) design. It presents methods of predicting the dependability of designed devices, design of devices with desired dependability and comparison of dependability of various SS. For that purpose, the authors set forth the fundamentals of the dependability theory for SS design, methods of collection and processing of data of equipment dependability based on the results of operation and special dependability tests. Methods, mathematical models are developed, the equipment architecture at the stage of design and manufacture is analyzed. The paper also cites the design ratios for various tested types of redundancy, lifetime extension of SC units based on the residual operating life estimation method. The existing methods of dependability analysis are classified and examined. The authors outline the problems of ambiguity of information of the input data in case of classical computing. The effect of nominal deviations of the external effects, irregularity of the failure rate, non-linear nature of the effect of external factors on the dependability are examined. The paper also takes a look at the way the external factors affect the dependability and the degree to which such factors are taken into consideration in the existing methods. It is noted that the qualitative, technical and organizational (design and software) requirements for dependability in the technical specifications for each stage of elements and SS development, shall be observed and confirmed at the respective stage of activities. The paper presents the methods of estimation of technical item operating life with the focus on those based on the physical premises of operating life depletion. Attention is drawn to the importance of the economic aspect in the research dedicated to SS lifetime extension.
Aim. To consider matters of dependability of highly critical non-recoverable space products with short operation life, whose failures are primarily caused by design and process engineering errors, manufacturing defects in the course of single-unit or small-scale production, as well as to define the methodological approach to ensuring the required reliability.Methods. Options were analysed for improving the dependability of entities with short operation life using the case study of single-use mechanical devices and the statistical approaches of the modern dependability theory, special methods of dependability of actuated mechanical assemblies, FMEA, Stage-Gate and ground experiments on single workout equivalents for each type of effect. Results. It was concluded that additional procedures need to be conducted for the purpose of predicting, mitigation and (or) eliminating possible failures as part of the design process using exactly the same approaches that cause failures, i.e., those of design and process engineering. The engineering approaches to dependability are based on early identification of possible causes of failures, which requires a qualified and systemic analysis aimed at identifying the functionality, performance and dependability of an entity, taking into account critical output parameters and probabilistic indicators that affect the performance of the required functions with the allowable probability of failure. The solution is found using a generalized parametric model of operation and design engineering analysis of dependability.Conclusion. For highly critical non-recoverable space entities with short operation life, the reliability requirements should be considered primarily in terms financial, economic, safetyrelated and reputational risks associated with the loss of spacecraft. From a design engineer’s standpoint, the number of nines after the decimal point (rounded to a smaller number of nines for increased confidence) should be seen as the indicator for the application of the appropriate approaches to ensuring the required reliability at the stage of product design. In case of two nines after the decimal point it is quite acceptable to use analytical and experimental verification techniques common to the aerospace industry, i.e., dependability calculations using the statistical methods of the modern dependability theory and performance indicators, FMEA and Stage-Gate, ground experiments on single workout equivalents for each type of effect. As the required number of nines grows, it is advisable to also use early failure prevention methods, one of which is the design engineering analysis of dependability that enables designers to adopt substantiated design solutions on the basis of engineering disciplines and design and process engineering methods of ensuring quality and dependability. The choice of either of the above dependability strategies is determined solely by the developer’s awareness and understanding of potential hazards, which allows managing the risk of potential rare failures or reasonably refusing to do so.
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