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Testing Strategies for Model-Based Development

This report presents an approach for testing artifacts generated in a model-based development process. This approach divides the traditional testing process into two parts: requirements-based testing (validation testing) which determines whether the model implements the high-level requirements and model-based testing (conformance testing) which determines whether the code generated from a model is behaviorally equivalent to the model. The goals of the two processes differ significantly and this report explores suitable testing metrics and automation strategies for each. To support requirements-based testing, we define novel objective requirements coverage metrics similar to existing specification and code coverage metrics. For model-based testing, we briefly describe automation strategies and examine the fault-finding capability of different structural coverage metrics using tests automatically generated from the model.

Heimdahl, Mats P. E.↗

Results of tests of advanced flexible insulation vortex and flow environments in the North American Aerodynamics Laboratory lowspeed wind tunnel using 0.0405-scale Space Shuttle Orbiter model 16-0 (test OA-309)

An experimental investigation (Test OA-309) was conducted using 0.0405-scale Space Shuttle Orbiter Model 16-0 in the North American Aerodynamics Laboratory 7.75 x 11.00-foot Lowspeed Wind Tunnel. The primary purpose was to locate and study any flow conditions or vortices that might have caused damage to the Advanced Flexible Reusable Surface Insulation (AFRSI) during the Space Transportation System STS-6 mission. A secondary objective was to evaluate vortex generators to be used for Wind Tunnel Test OS-314. Flowfield visualization was obtained by means of smoke, tufts, and oil flow. The test was conducted at Mach numbers between 0.07 and 0.23 and at dynamic pressures between 7 and 35 pounds per square foot. The angle-of-attack range of the model was -5 degrees through 35 degrees at 0 or 2 degrees of sideslip, while roll angle was held constant at zero degrees. The vortex generators were studied at angles of 0, 5, 10, and 15 degrees.

Marshall, B. A.↗

MODELING A SPENT NUCLEAR FUEL CASK SEISMIC TEST

The US Department of Energy Spent Fuel and Waste Science and Technology (SFWST) program is planning to conduct a series of full-scale shake table tests to simulate hypothetical earthquake conditions and record the response of surrogate spent nuclear fuel (SNF) assemblies in a canister dry storage system mockup. The shake table motions will represent a range of hypothetical earthquake conditions at hypothetical locations in the continental US to generally define the range of mechanical loads that SNF can be expected to experience during extended dry storage periods. The earthquake conditions will represent seismic hazards in the 2,000-to-20,000-year return period range. The test will use instrumented pressurized water reactor fuel assemblies with surrogate mass inside the fuel rods instead of radioactive fuel pellets. Dummy assemblies with similar mass and dimensions to actual fuel assemblies will occupy the rest of the fuel assembly locations in a SNF canister that holds 32 fuel assemblies. The canister will be located inside a mockup vertical concrete cask. Instrumentation will record the motion of the major components of the complex dynamic system, and strain gauges will be used to record the cladding strain at select locations. Preparations for the test require modeling predictions to identify the range of response of the system and to help select specific earthquake cases to be simulated on the shake table from a large set of potential cases. This paper describes the pretest nonlinear finite element modeling efforts that have been completed to date, including cask system level modeling and fuel assembly modeling in LS-DYNA. The cask system level models are critical for anticipating sliding or tipping of an unanchored cask during the test. The fuel assembly model is needed to estimate the range of cladding strain response and fuel assembly structural response to be expected during the test and cladding strain measurements will be key metrics for model validation and the development of modeling best practices after the test is concluded.

Klymyshyn, Nicholas A.↗

Design and testing of a model CELSS chamber robot

A robot system for use in an enclosed environment was designed and tested. The conceptual design will be used to assist in research performed by the Controlled Ecological Life Support System (CELSS) project. Design specifications include maximum load capacity, operation at specified environmental conditions, low maintenance, and safety. The robot system must not be hazardous to the sealed environment, and be capable of stowing and deploying within a minimum area of the CELSS chamber facility. This design consists of a telescoping robot arm that slides vertically on a shaft positioned in the center of the CELSS chamber. The telescoping robot arm consists of a series of links which can be fully extended to a length equal to the radius of the working envelope of the CELSS chamber. The vertical motion of the robot arm is achieved through the use of a combination ball screw/ball spline actuator system. The robot arm rotates cylindrically about the vertical axis through use of a turntable bearing attached to a central mounting structure fitted to the actuator shaft. The shaft is installed in an overhead rail system allowing the entire structure to be stowed and deployed within the CELSS chamber. The overhead rail system is located above the chamber's upper lamps and extends to the center of the CELSS chamber. The mounting interface of the actuator shaft and rail system allows the entire actuator shaft to be detached and removed from the CELSS chamber. When the actuator shaft is deployed, it is held fixed at the bottom of the chamber by placing a square knob on the bottom of the shaft into a recessed square fitting in the bottom of the chamber floor. A support boot ensures the rigidity of the shaft. Three student teams combined into one group designed a model of the CELSS chamber robot that they could build. They investigated materials, availability, and strength in their design. After the model arm and stand were built, the class performed pre-tests on the entire system. A stability pre-test was used to determine whether the model robot arm would tip over on the stand when it was fully extended. Results showed the stand tipped when 50 Newtons were applied horizontally to the top of the vertical shaft while the arm was fully extended. This proved that it was stable. Another pre-test was the actuator slip test used to determine if there is an adequate coefficient of friction between the actuator drive wheels and drive cable to enable the actuator to fully extend and retract the arm. This pre-test revealed that the coefficient of friction was not large enough to prevent slippage. Sandpaper was glued to the drive wheel and this eliminated the slippage problem. The class preformed a fit test in the CELSS chamber to ensure that the completed robot arm is capable of reaching the entire working envelope. The robot was centered in the chamber and the arm was fully extended to the sides of the chamber. The arm was also able to retract to clear the drain pipes separating the upper and lower plant trays.

Davis, Mark↗

NASA 5.2%-Scale High Lift Common Research Model (CRM-HL) Test in the National Transonic Facility (NTF)

Problem: Predicting CL,max and assessing transition, turbulence models, and Reynolds number effect predictions in CFD requires wind tunnel data for comparison. Objective: Expand the CFD validation database by running multiple models designed using the same reference geometry in various wind tunnels around the world. The wind tunnel data and model geometry will be open source to allow for CFD validation use. Approach: Run the NASA 5.2%-scale High Lift Common Research Model (CRM-HL) semi-span model at the National Transonic Facility (NTF). Test the model at chord Reynolds numbers (Rec) between 1.6 million and 30 million and at varying Q/Es to assess Reynolds number effects and aeroelasticity affects on the model, while collecting force and moment, pressure and wing deformation data. Test the model with ice shapes installed on the leading edges. Results: Ran eight model configurations, including four landing, two landing with ice shapes installed, and two takeoff configurations. Ran in air (120°F) and nitrogen operations (-50°F, -180°F and -250°F) at 7 different chord Reynolds numbers. The data compare well with previous tests of the same model at DLR (The Germany Aerospace Center) and the 14- by 22-Foot Subsonic Tunnel (14x22). Significance: Provided valuable high Reynolds number data on a high lift configuration to the worldwide research community. Provide icing data at flight Reynolds number to the research community.

CRM-HL↗

Starburst modeling of M82 - Test case for a biased initial mass function

We compute starburst models for M82, making use of recent theoretical tracks of stellar evolution. Detailed comparisons of our models and those of others demonstrate this technique to be quite reliable, with relatively little change in output parameters as a function of the selection of theoretical tracks or of estimates of the observational characteristics of the stars along these tracks. The models are matched to the observational constraints for M82 summarized by McLeod et al. (1993). The rate of star formation and time of observation were thoroughly optimized to produce the most favorable fit to the observations, but we still found that the recently proposed forms for the solar-neighborhood IMF cannot produce starbursts adequate to fit the observations of this galaxy. We then explored adjustments to the shape of the IMF to improve the fit to M82. We find (1) the shape of the IMF for high-mass stars need not be different from that observed locally; and (2) the most likely modification to the IMF in M82 is that stars with masses below a few solar masses form much less commonly than in the solar neighborhood.

Rieke, G. H.↗

Variable Stiffness Spar Wind-Tunnel Model Development and Testing

The concept of exploiting wing flexibility to improve aerodynamic performance was investigated in the wind tunnel by employing multiple control surfaces and by varying wing structural stiffness via a Variable Stiffness Spar (VSS) mechanism. High design loads compromised the VSS effectiveness because the aerodynamic wind-tunnel model was much stiffer than desired in order to meet the strength requirements. Results from tests of the model include stiffness and modal data, model deformation data, aerodynamic loads, static control surface derivatives, and fuselage standoff pressure data. Effects of the VSS on the stiffness and modal characteristics, lift curve slope, and control surface effectiveness are discussed. The VSS had the most effect on the rolling moment generated by the leading-edge outboard flap at subsonic speeds. The effects of the VSS for the other control surfaces and speed regimes were less. The difficulties encountered and the ability of the VSS to alter the aeroelastic characteristics of the wing emphasize the need for the development of improved design and construction methods for static aeroelastic models. The data collected and presented is valuable in terms of understanding static aeroelastic wind-tunnel model development.

Florance, James R.↗

Low speed wind tunnel tests of 1/10-scale model of a blended-arrow supersonic cruise aircraft

Low speed static force tests have been conducted in a full scale tunnel to determine the low speed aerodynamic characteristics of a 1/10-scale model of a blended-arrow supersonic cruise aircraft. A clean configuration and a high lift configuration with several combinations of leading- and trailing-edge flaps to provide improved lift and longitudinal stability in the landing and takeoff modes were used. The tests were made at angles of attack from about -6 deg to 30 deg, sideslip angles from -5 deg to 10 deg, and Reynolds numbers from 6.78 x 1 million to 13.85 x 1 million corresponding to test velocities of 41 to 85 knots.

Mclemore, H. C.↗

Tanks Test of a Model of the Hull of the Navy PB-1 Flying Boat - N.A.C.A. Model 52

A model of the hull of the Navy PB-1 flying boat was tested in the N.A.C.A. tank as part of a program intended to provide information regarding the water performance of hulls of flying boats of earlier design for which hydrodynamic data have heretofore been unavailable. Tests were made according to the general method over the range of practical loadings with the model both fixed in trim and free to trim. A free-to-trim test according to the specific method was also made for the design load and take-off speed corresponding to those of the full-scale flying boat. The resistance obtained from the fixed-trim test was found to be about the same as that of the model of the NC flying-boat hull, and greater at the hump but smaller at high speeds than that of a model of the Sikorsky S-40 flying-boat hull.

Allison, John M↗

Wind tunnel test of a model rotor with a free-tip

A model helicopter rotor with a free tip was tested in a wind tunnel to show the effect of the free tip on rotor performance and oscillatory loads. The free-tip rotor has blade tips that are free to pitch independently of the remainder of the blade. A nearly constant pitching moment is applied to the tip so the tip will produce a nearly steady lift around the azimuth. The aerodynamic development of the free tip is reviewed. The development process concentrated on configuring the tip to have the capability of fast response to angle-of-attack perturbations. Wind tunnel test results show the free-tip rotor configuration requires less power than a fixed-tip configuration in forward flight. In addition, the free tip causes substantial reduction in blade-flapwise vibratory loads. However, blade-chordwise loads were increased. Pitch-link vibratory loads were also reduced by the free-tip configuration. Discussion is presented on the reasons that the use of the free tip caused reduced power and smaller vibratory loads.

Stroub, R. H.↗

Observations of the magnetopause current layer: Cases with no boundary layer and tests of recent models

Evidence for the probable existence of magnetospheric boundary layers was first presented by Hones, et al. (1972), based on VELA satellite plasma observations (no magnetic field measurements were obtained). This magnetotail boundary layer is now known to be the tailward extension of the high-latitude boundary layer or plasma mantle (first uniquely identified using HEOS 2 plasma and field observations by Rosenbauer et al., 1975) and the low-latitude boundary layer (first uniquely identified using IMP 6 plasma and field observations by Eastman et al., 1976). The magnetospheric boundary layer is the region of magnetosheath-like plasma located Earthward of, but generally contiguous with the magnetopause. This boundary layer is typically identified by comparing low-energy (less than 10 keV) ion spectra across the magnetopause. Low-energy electron measurements are also useful for identifying the boundary layer because the shocked solar wind or magnetosheath has a characteristic spectral signature for electrons as well. However, there are magnetopause crossings where low-energy electrons might suggest a depletion layer outside the magnetopause even though the traditional field-rotation signature indicates that this same region is a boundary layer Earthward of the current layer. Our analyses avoided crossings which exhibit such ambiguities. Pristine magnetopause crossings are magnetopause crossings for which the current layer is well defined and for which there is no adjoining magnetospheric boundary layer as defined above. Although most magnetopause models to date apply to such crossings, few comparisons between such theory and observations of pristine magnetopause crossings have been made because most crossings have an associated magnetospheric boundary layer which significantly affects the applicable boundary conditions for the magnetopause current layer. Furthermore, almost no observational studies of magnetopause microstructure have been done even though key theoretical issues have been discussed for over two decades. This is because plasma instruments deployed prior to the ISEE and AMPTE missions did not have the required time resolution and most ISEE investigations to-date have focused on tests of MHD plasma models, especially reconnection. More recently, many phenomenological and theoretical models have been developed to explain the existence and characteristics of the magnetospheric boundary layers with only limited success to date. The cases with no boundary layer treated in this study provide a contrary set of conditions to those observed with a boundary layer. For the measured parameters of such cases, a successful boundary layer model should predict no plasma penetration across the magnetopause. Thus, this research project provides the first direct observational tests of magnetopause models using pristine magnetopause crossings and provides important new results on magnetopause microstructure and associated kinetic processes.

Eastman, Timothy E.↗

The role of modeling and flight testing in rotorcraft parameter identification

The importance of recognizing that each lower-order model used for rotorcraft parameter identification has a limited range of applicability is illustrated in some detail. Examples are given to illustrate the use of conditioning the test input signals and the potential of using multi-axis test inputs to enhance the parameter identifiability. The paper discusses the benefits and limitations of using frequency sweeps as flight-test input signals for identification of frequency response for rotorcraft and for the subsequent fitting of parametric transfer-function models. This paper demonstrates the major role played by analytical modeling and the understanding of the physics involved in the rotorcraft flight dynamics, particularly understanding the limit of lower-order models, in achieving successful rotorcraft parameter identification.

Chen, R. T. N.↗

Icing testing in the large Modane wind-tunnel on full-scale and reduced scale models

Icing tests on full scale models of parts of aircraft (wings, tailplanes, radome) equipped with actual de-icing systems were carried out in the large Modane wind tunnel of ONERA. For studying icing on the Concorde, it was necessary to use a 1/6 scale half model. The equations governing the relevant parameter ratios to obtain reasonably good similitude water catching and ice accretion are recalled. Despite the inherent limitations of this particular kind of testing, i.e., the impossibility of duplicating both the Mach and Reynolds conditions for the main flow pattern, it is possible to obtain on a reduced scale model a reasonably good representation of icing cloud catching and of the shape of resulting ice accretion.

Charpin, F.↗

Solar Thermal Upper Stage Liquid Hydrogen Pressure Control Testing and Analytical Modeling

The demonstration of a unique liquid hydrogen (LH2) storage and feed system concept for solar thermal upper stage was cooperatively accomplished by a Boeing/NASA Marshall Space Flight Center team. The strategy was to balance thermodynamic venting with the engine thrusting timeline during a representative 30-day mission, thereby, assuring no vent losses. Using a 2 cubic m (71 cubic ft) LH2 tank, proof-of-concept testing consisted of an engineering checkout followed by a 30-day mission simulation. The data were used to anchor a combination of standard analyses and computational fluid dynamics (CFD) modeling. Dependence on orbital testing has been incrementally reduced as CFD codes, combined with standard modeling, continue to be challenged with test data such as this.

Olsen, A. D.↗

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