Model-based FDI for Agile Spacecraft with Multiple Actuators Working Simultaneously E. Lopez i de la Encarnacion Technische Universiteit Delft
Model-based FDI for Agile Spacecraft with Multiple Actuators Working Simultaneously
by E. Lopez i de la Encarnacion
in partial fulfillement of the requirements to obtain the degree of Master of Science in Aerospace Engineering at the Delft University of Technology, to be defended publicly on 12th June 2019 at 9.00am.
Student number: 4617266 Project duration: July 16, 2018 – June 12, 2019 Thesis committee: Dr.ir. R. Fónod, TU Delft, supervisor Dr. A. Cervone, TU Delft, committee chair Dr.ir. E. van Kampen, TU Delft, external examinator
An electronic version of this thesis is available at http://repository.tudelft.nl/. Cover image credits: European Space Agency
Preface
This report presents the MSc thesis project Model-based FDI for Agile Spacecraft with Multiple Actuators Working Simultaneously, the bases of which is a novel fault detection and isolation strategy applied to agile spacecrafts that use multiple actuators together and tested using Monte Carlo campaigns. It has been written to partially fulfill the requirements to obtain the degree of Master of Science in Aerospace Engineering at the Delft University of Technology. The research project and the writing of this thesis has been done from July 2018 to May 2019.
The development of this research project has been done at Airbus Defence and Space GmbH, in Friedrichshafen, Germany, within the Attitude and Orbit Control System and Guidance, Navigation, and Control (AOCS/GNC) department. The definition of the thesis goals and scope was done in accordance with my company supervisor, Patrick Bergner, and my thesis supervisor, Róbert Fónod. The thesis presented some difficulties, the fault detection and isolation field is very broad and there are so many strategies that can be used to achieve the defined goals. However, a good literature research and the help and advice of both my supervisors, who were always available and willing to respond to my inquiries, allowed me to accomplish this thesis with satisfaction. In addition, this project allowed me to submit, together with both supervisors, a conference paper to the Automatic Control in Aerospace 2019 (ACA2019) conference, which has been accepted for publication.
Therefore, I would to sincerely thank both my supervisors for their support, guidance, and supervision during all these months. I also want to thank all the Airbus colleagues, employ- ees, interns, and thesis students, who help me going through and gave their advice when I needed it. To my family and friends: I would like to thank you for supporting me and keep me motivated when I was discouraged. And specially thank to my parents who have always been there for me and encouraged me to pursue my dreams.
I hope you find it interesting and enjoy reading it.
E. Lopez i de la Encarnacion Sabadell, May 2019
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Abstract
Current and future space missions require agile and reliable spacecraft capable of trailing and keeping the required attitude. Most of the agile spacecraft missions are near-Earth based but some are placed far away from Earth and its influence. One example of such missions is the Athena mission, which requires the spacecraft to perform fast and large-angle attitude slew manoeuvres. Such manoeuvres often imply simultaneous use of multiple actuators such as thrusters and reaction wheels (RWs). A fault in any of these actuators might lead to partial or full damage of sensitive spacecraft instruments. In this research project, a novel model- based Fault Detection and Isolation (FDI) strategy is proposed, which is able to detect and isolate various actuator faults, such as stuck-open/closed thruster, thruster leakage, loss of effectiveness of all thrusters, and change of RW friction torque due to change of Coulomb and/or viscosity factor. Moreover, the proposed FDI strategy is also able to detect and isolate faults affecting the RWs tachometer. The design of the FDI algorithm is based on a multi- plicative extended Kalman filter, a generalised likelihood ratio thresholding of the residual signals, and a logic algorithm which unequivocally link the faults to the symptoms. The performance and robustness of the proposed FDI strategy are evaluated using Monte Carlo simulations and carefully defined FDI performance indices. In addition, the influence of faults’ magnitudes, times of fault occurrence, and uncertainties’ magnitudes on the FDI sys- tem performance are evaluated. Preliminary results suggest promising performance in terms of detection/isolation times, miss-detection/isolation rates, and false alarm rates. Also, un- certainties on the spacecraft inertia seem to have a negative impact on the FDI performance. In order to fully understand the research project presented here, graduate-level knowledge on rigid body dynamics and kinematics, control theory, and filters applied to estimation might be required. If any of these areas are not known by the reader, it is recommended to read some of the associated literature referenced in the bibliography.
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Contents
List of Figures ix List of Tables xi Nomenclature xvi Notation xvi 1 Introduction 1 1.1 Background ...... 1 1.2 Motivation ...... 3 1.3 The Scope of this Research ...... 4 1.4 Research Objectives, Framework, and Questions ...... 4 1.4.1 Research Objectives ...... 4 1.4.2 Research Framework ...... 5 1.4.3 Research Questions ...... 5 2 Theoretical Background 7 2.1 Athena Mission Description ...... 7 2.1.1 Space Environment ...... 7 2.1.2 Spacecraft Characteristics ...... 7 2.1.3 AOCS Equipment...... 8 2.2 Fault Detection and Isolation...... 9 2.2.1 FDI Architectures ...... 10 2.2.2 Model-Based FDI ...... 12 2.3 Spacecraft Attitude Representation ...... 15 3 Study Case Description and Methodology 17 3.1 Definition of the Study Case ...... 17 3.1.1 Environment ...... 17 3.1.2 AOCS Equipment: Sensors and Actuators ...... 18 3.1.3 Spacecraft’s Dynamics and Kinematics ...... 20 3.1.4 Faults ...... 21 3.1.5 Uncertainties ...... 22 3.2 Methodology for Evaluation of the FDI System ...... 22 3.2.1 Test Campaigns ...... 22 3.2.2 Evaluation Criteria ...... 23 3.2.3 Post-Processing ...... 24 4 Proposed FDI Strategy 25 4.1 FDI Strategy ...... 25 4.1.1 Kalman Filter ...... 25 4.1.2 Extended Kalman Filter ...... 26 4.1.3 Multiplicative Extended Kalman Filter ...... 27 4.1.4 State Estimation ...... 29 4.1.5 Residual Generation ...... 32 4.1.6 Fault Detection Algorithm ...... 32 4.1.7 Fault Isolation Algorithm ...... 33
vii viii Contents
5 Simulation Results 35 5.1 Simulator ...... 35 5.1.1 Workflow ...... 35 5.1.2 Structure and Functionality...... 36 5.1.3 Missing Features in the Simulator ...... 37 5.2 Study Case Parameters Definition...... 39 5.3 Sample Runs Analysis ...... 43 5.3.1 Fault-Free...... 43 5.3.2 Leakage Fault ...... 44 5.3.3 Loss of Effectiveness Fault ...... 45 5.3.4 Stuck Close Fault...... 46 5.3.5 Stuck Open Fault ...... 47 5.3.6 Reaction Wheel Friction Fault ...... 48 5.3.7 Reaction Wheel Tachometer Fault...... 49 5.4 Monte Carlo Analysis...... 49 5.4.1 Test Campaign Without Uncertainties ...... 50 5.4.2 Test Campaign With Uncertainties...... 59 5.5 Discussion on Simulation Results ...... 64 6 Conclusions and Recommendations 65 6.1 Research Sub-Questions ...... 65 6.1.1 Sub-Question: Study Case Model ...... 65 6.1.2 Sub-Question: Methodology ...... 66 6.1.3 Sub-Question: AOCS FDI System...... 66 6.1.4 Sub-Question: FDI System Performance ...... 67 6.2 Research Question ...... 67 6.3 Recommendations and Future Work ...... 68 A Appendix: Derivations 71 A.1 Process Noise Matrix Q ...... 71 A.2 Power Spectral Density and Variance ...... 74 B Appendix: Validation and Verification 75 B.1 Thruster Reaction Control System...... 75 B.1.1 Individual Test ...... 75 B.1.2 Multiple Test ...... 76 B.1.3 Monte Carlo Test ...... 76 B.2 Kalman Filter ...... 78 C Appendix: Additional Simulation Figures 81 C.1 Sample Runs of Interest ...... 81 C.1.1 Stuck Open Fault With Highest Time To Detection ...... 81 C.1.2 Stuck Close Fault With Highest Time To Detection ...... 82 C.2 Additional Simulation Results Figures ...... 83 C.3 Uncertainties Correlations ...... 84 Bibliography 85 List of Figures
1.1 Research framework ...... 6
2.1 L2 Earth-Sun Halo Orbit...... 8 2.2 ESA design: Athena spacecraft in deployed configuration...... 8 2.3 Hybrid expert based architecture...... 10 2.4 Simplified model-based FDI architecture...... 11 2.5 General model-based FDI architecture...... 13
3.1 ESA design: Athena spacecraft in deployed configuration with fixed-body frame. 20
5.1 Top-level architecture of the GAFE Simulator. Source: GAFE Users’ Manual. . 36 5.2 Comparison between real scenario PWM signal and simulation scenario PWM signal of single thruster during a single cycle...... 39 5.3 Comparation between real scenario PWM signal and simulation scenario PWM signal of single thruster during a single cycle...... 39 5.4 Maximum, minimum, and limiting generated torque per axis...... 40 5.5 RCS torque envelope...... 40 5.6 Evolution of the spacecraft attitude...... 41 5.7 Fault-free case...... 43 5.8 Force [N] per 푖푡ℎ thruster over time in fault-free case...... 44 5.9 Faulty thruster force in Leakage fault case...... 44 5.10Leakage fault case...... 44 5.11Spacecraft’s angular rates in fixed-body frame for leakage fault case...... 45 5.12Force [N] per thruster over time in LOE fault...... 46 5.13LOE fault case...... 46 5.14Faulty thruster force in stuck close fault case...... 46 5.15Stuck close fault case...... 47 5.16Faulty thruster force in stuck open fault case...... 47 5.17Stuck open fault case...... 48 5.18RW friction fault case...... 48 5.19RW tachometer fault case...... 50 5.20Leakage fault: simulation parameters histograms...... 51 5.21Leakage fault: influences w.r.t. detection performance...... 52 5.22Leakage fault: influences w.r.t. isolation performance...... 53 5.23LOE fault: simulation parameters histograms...... 53 5.24LOE fault: influences w.r.t. detection performance...... 54 5.25LOE fault: time of fault occurrence vs fault’s magnitude...... 54 5.26Stuck Close fault: simulation parameters histograms...... 55 5.27Stuck Close fault: influences w.r.t. detection performance...... 55 5.28Stuck Open fault: simulation parameters histograms...... 56 5.29Stuck Open fault: influences w.r.t. detection performance...... 56 5.30RW friction fault: simulation parameters histograms...... 56 5.31RW friction fault: influences w.r.t. detection performance...... 57 5.32RW tachometed fault: simulation parameters histograms...... 58 5.33RW tachometer fault: influences w.r.t. detection performance...... 58 5.34Uncertainties histograms...... 59 5.35Uncertainties correlation coefficients for global results...... 61 5.36Fault-free simulations’ inertia uncertainties magnitudes...... 62 5.37Inertia uncertainty magnitudes vs false alarm...... 63
ix x List of Figures
5.38Inertia uncertainty probability function distribution for no-false/false alarm cases...... 63
B.1 Single RCS cycle delivered forces per thruster...... 76 B.2 Commanded versus delivered forces and torques for a single RCS cycle. .... 76 B.3 Multiple RCS cycles delivered forces per thruster...... 77 B.4 Commanded versus delivered forces/torques for multiple RCS cycles...... 77 B.5 Commanded versus delivered forces/torques and relative errors of 50 runs. .. 77 B.6 Mean and maximum relative errors...... 78 B.7 Spacecraft angular rate true error consistency check...... 79 B.8 RWs angular rates true error consistency check...... 79 B.9 RWs friction torques true error consistency check...... 79 B.10Spacecraft angular rates measurement error consistency check...... 80 B.11RWs angular rates measurement error consistency check...... 80
C.1 Stuck open fault case with highest time to detection...... 81 C.2 Stuck close fault case with highest time to detection...... 83 C.3 Lineal scale representation...... 83 C.4 Uncertainties correlation coefficients...... 84 List of Tables
4.1 Fault signatures...... 34
5.1 Spacecraft and FDI related parameters...... 42 5.2 GLR means and variances and decision taking algorithms design parameters. . 42 5.3 MC related parameters...... 50 5.4 Campaign without uncertainties results...... 50 5.5 Campaign with uncertainties results...... 60 5.6 Percentage differences between results from no-uncertainty and uncertainty campaigns...... 60
B.1 RCS validation and verification parameters ...... 75 B.2 True errors consistency check results...... 80 B.3 Measurement errors consistency check results...... 80
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Nomenclature
Acronyms
AEOS Agile Earth Observing Satellites AOCS Attitude and Orbit Control System CI Confidence Interval
CMG Control Moment Gyro CoM Center of Mass CUSUM Cumulative Sum DEPFET Depleted P-channel Fiel Deffect Transistor
EKF Extended Kalman Filter ESA European Space Agency FDI Fault Detection, and Isolation
FDIR Fault Detection, Isolation, and Recovery GLR Generalized Likelihood Ratio GNC Guidance, Navigation, and Control KF Kalman Filter
LOE Loss Of Effectiveness MC Monte Carlo RCS Reaction Control System
RMU Rate Measurement Unit RW Reaction Wheel STR Star Tracker UFK Unscented Kalman Filter Attitude Representation
퐀 Euler angles 퐠 Gibbs vector 퐪 Quaternion
퐑 Rotation matrix
퐯 Vector in body frame
퐯 Vector in reference frame
xiii xiv List of Tables
AOCS Equipment
휒 Function that models different faults in a thruster
휖 Misalignment angle
휙 Scalar variable that models if a thruster is faulty
휓 Scalar variable that models reaction wheel measurement fault
흎 Reaction wheel angular rate
흎 Spacecraft angular rate 휽(⋅, ⋅) Rotation function of a vector
흋(⋅) Quaternion rotation function for noise in Euler angles
흑(⋅) Quaternion rotation function for misalignment angle
퐛 Directional force of 푖푡ℎ thruster
퐛 Directional torque of 푖푡ℎ thruster
퐝 Direction of 푖푡ℎ thruster
퐡 Angular momentum vector associated with reaction wheels
퐉 Reaction wheel inertia
퐉 Spacecraft inertia matrix
퐫 Vector position of 푖푡ℎ thruster w.r.t CoM 퐓 Torque
퐮 Inputs
휉 Scalar variable that models reaction wheel viscous factor fault
휉 Scalar variable that models reaction wheel Coulomb factor fault
휁 Coulomb friction torque constant
휁 Viscous friction torque constant
푐 Total torque of 푖푡ℎ reaction wheel
푓 Coulomb friction
퐹 Thruster force
푓 Viscous friction
푚 Fault magnitude with 푖 ∈ {푙푒푎푘,푙표푒,푚푒푎푠,푣,푐}
푚 Directional vector of 푖푡ℎ reaction wheel 푁 Number of elements
Algorithms
훿퐠 Error Gibbs vector
훿퐪 Error quaternion
훾 Fixed threshold accounting for the RW’s friction characteristics List of Tables xv
Γ Decision taking threshold for 푖푡ℎ GLR test signal
휆 Decision test signal for 푖푡ℎ GLR test signal
퐁 Geometric matrix of thruster noise influence on body frame 퐅 Jacobian matrix of f(x,u) 퐠 GLR test signals 퐇 Sensitivity matrix
퐡 Observation model
퐊 Kalman gain matrix
퐌 Fault signature matrix
퐌 Misalignment-free matrix mapping the estimated RWs’torque contributions into the spacecraft body-fixed frame
퐏 Covariance matrix of the states
퐐 Discrete process noise matrix 퐫 Residual signals
퐑 Measurement noise matrix 퐮 Inputs 퐱 States
퐳 Sensors measurements 휀 Very small constant 퐿 Moving time window Monte Carlo Campaigns Δ Half the confidence interval 푗̂ Fraction of success 푣̂ Fraction of failure
푁 Number of Monte Carlo runs
푡 Fault time of occurrence
푧 / Upper tail of the normal distribution set by the confidence level Statistics 훿 Diract Delta function 휅 Probability function scalar parameter ℋ Hypothesis 휇 Mean value 휎 Standard deviation 휎 Variance 휼(푡) Continuous-time zero-mean Gaussian white noise signal function xvi List of Tables
휼 Discrete-time zero-mean Gaussian white noise vector 퐥 Vector of independent random variables 퐐(푡) Process noise PDS matrix
퐐 Discrete process noise matrix
퐑 Auto-correlation matrix of noise
퐫 Auto-correlation function of noise
퐒 Power spectral density function of noise
퐾 Unknown change time
푆 Power spectral density constant value for white noise Notation
• Vector and matrix: bold and not cursive with dimensions as subindices, if necessary, e.g., m, M , and M . • 푥 and 퐱 stand for a variable and vector variable, respectively. • ̂푥 is the estimate of 푥. • ̇푥= is the time derivative of 푥. • ℝ × defines a set of real numbers with 푚 × 푛 dimensions.
• The norm for vector 퐱 is defined as ||퐱||. • Let 퐌 ∈ ℝ × be a matrix with real values, 퐌 ∈ ℝ × be its transpose. • Let 퐌 ∈ ℝ × be a matrix with real values, 퐌 ∈ ℝ × be its inverse.
• The diag(푥 푥 … 푥 ) is a diagonal matrix with 푥 , ∀푖 ∈ [1 2 … 푛] as main diagonal elements and zero on the off-diagonal elements.