Reliability Case Study of COTS Storage on the Jilin-1 KF Satellite: On-Board Operations, Failure Analysis, and Closed-Loop Management

In recent years, the rapid development of commercial satellite projects, such as low-Earth orbit (LEO) communication and remote sensing constellations, has driven the satellite industry toward low-cost, rapid development, and large-scale deployment. Commercial off-the-shelf (COTS) components have been widely adopted across various commercial satellite platforms due to their advantages of low cost, high performance, and plug-and-play availability. However, the space environment is complex and hostile. COTS components were not originally designed for such conditions, and they often lack systematically flight-verified protective frameworks, making their reliability issues a core bottleneck limiting their extensive application in critical missions. This paper focuses on COTS solid-state drives (SSDs) onboard the Jilin-1 KF satellite and presents a full-lifecycle reliability practice covering component selection, system design, on-orbit operation, and failure feedback. The core contribution lies in proposing a full-lifecycle methodology that integrates proactive design—including multi-module redundancy architecture and targeted environmental stress screening—with on-orbit data monitoring and failure cause analysis. Through fault tree analysis, on-orbit data mining, and statistical analysis, it was found that SSD failures show a significant correlation with high-energy particle radiation in the South Atlantic Anomaly region. Building on this key spatial correlation, the on-orbit failure mode was successfully reproduced via proton irradiation experiments, confirming the mechanism of radiation-induced SSD damage and providing a basis for subsequent model development and management decisions. The study demonstrates that although individual COTS SSDs exhibit a certain failure rate, reasonable design, protection, and testing can enhance the on-orbit survivability of storage systems using COTS components. More broadly, by providing a validated closed-loop paradigm—encompassing design, flight verification and feedback, and iterative improvement—we enable the reliable use of COTS components in future cost-sensitive, high-performance satellite missions, adopting system-level solutions to balance cost and reliability without being confined to expensive radiation-hardened products.