Using PHM to measure equipment usable life on the Air Force's next generation reusable space booster

Abstract

The U.S. Air Force procures many launch vehicles and launch vehicle services to place their satellites at their desired location in space. The equipment on-board these satellite and launch vehicle often suffer from premature failures that result in the total loss of the satellite or a shortened mission life sometimes requiring the purchase of a replacement satellite and launch vehicle. The Air Force uses its EELV to launch its high priority satellites. Due to a rise in the cost of purchasing a launch using the Air Force's EELV from $72M in 1997 to as high as $475M per launch today, the Air Force is working to replace the EELV with a reusable space booster (RSB). The RSB will be similar in design and operations to the recently cancelled NASA reusable space booster known as the Space Shuttle. If the Air Force uses the same process that procures the EELV and other launch vehicles and satellites, the RSB will also suffer from premature equipment failures thus putting the payloads at a similar high risk of mission failure. The RSB is expected to lower each launch cost by 50% compared to the EELV. The development of the RSB offers the Air Force an opportunity to use a new reliability paradigm that includes a prognostic and health management program and a condition-based maintenance program. These both require using intelligent, decision making self-prognostic equipment The prognostic and health management program and its condition-based maintenance program allows increases in RSB equipment usable life, lower logistics and maintenance costs, while increasing safety and mission assurance. The PHM removes many decisions from personnel that, in the past resulted in catastrophic failures and loss of life. Adding intelligent, decision-making self-prognostic equipment to the RSB will further decrease launch costs while decreasing risk and increasing safety and mission assurance.