Plan and Progress on Experimental Validation of Computational Small Rotor Design Optimization Tools
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New simulator for multilevel optimization of complex hierarchical systems reduces cost of analysis in experimentation with multilevel design-optimization algorithms. Computer program mimics qualitative behavior and data couplings that occur among subsystems of complex engineering system, such as car, aircraft, or building. Eliminates engineering analyses in subsystems by replacing them with judiciously-chosen analytical functions. Serves as tool for development of strategy for multilevel optimization of design.
An optimization-based integrated design approach for flexible space structures is experimentally validated using three types of dissipative controllers, including static, dynamic, and LQG dissipative controllers. The nominal phase-0 of the controls structure interaction evolutional model (CEM) structure is redesigned to minimize the average control power required to maintain specified root-mean-square line-of-sight pointing error under persistent disturbances. The redesign structure, phase-1 CEM, was assembled and tested against phase-0 CEM. It is analytically and experimentally demonstrated that integrated controls-structures design is substantially superior to that obtained through the traditional sequential approach. The capability of a software design tool based on an automated design procedure in a unified environment for structural and control designs is demonstrated.
The detailed design of two candidate topologies for the Space Platform battery discharger, a four module boost converter (FMBC) and a voltage-fed push-pull autotransformer (VFPPAT), is presented. Each has unique problems. The FMBC requires careful design and analysis in order to obtain good dynamic performance. This is due to the presence of a right-half-plane (RHP) zero in the control-to-output transfer function. The VFPPAT presents a challenging power stage design in order to yield high efficiency and light component weight. The authors describe the design of each of these converters and compare their efficiency, weight, and dynamic characteristics.
Progress in aerodynamics over the past 50 years has been evidenced by the development of increasingly sophisticated and efficient flight vehicles throughout the flight spectrum. Advances have generally arisen in an evolutionary manner from experience gained in wind tunnel testing, flight testing, and improvements in analytical and computational capabilities. As a result of this evolutionary development, both military and commercial vehicles operate at a relatively high efficiency level. This observation plus the fact that airplanes have not changed appreciably in outward appearance over recent years has led some skeptics to conclude incorrectly that aerodynamics is a mature technology, with little to be gained from further developments in the field. It is of interest to note that progress in aerodynamics has occurred without a thorough understanding of the fundamental physics of flow, turbulence, vortex dynamics, and separated flow, for example. The present understanding of transition, turbulence, and boundary layer separation is actually very limited. However, these fundamental flow phenomena provide the key to reducing the viscous drag of aircraft. Drag reduction provides the greatest potential for increased flight efficiency from the standpoint of both saving energy and maximizing performance. Recent advances have led to innovative concepts for reducing turbulent friction drag by modifying the turbulent structure within the boundary layer. Further advances in this basic area should lead to methods for reducing skin friction drag significantly. The current challenges for military aircraft open entirely new fields of investigation for the aerodynamicist. The ability through very high speed information processing technology to totally integrate the flight and propulsion controls can permit an aircraft to fly with "complete abandon," avoiding departure, buffet, and other undesirable characteristics. To utilize these new control concepts, complex aerodynamic phenomena will have to be understood, predicted, and controlled. Current requirements for military aircraft include configuration optimization through a widened envelope from subsonic to supersonic and from low to high angles of attack. This task is further complicated by requirements for control of observables. These challenging new designs do not have the luxury of a large experimental data base from which to optimize for various parameter combinations. Consequently, there exists a strong need for better techniques, both experimental and computational, to permit design optimization in a complete sense.
Optimal design procedure as experimental design finite decision problem, using Bayes and minimax techniques
A design of solar cells with reduced junction area on the cell surface is investigated for reduction of saturation current and increase in open-circuit voltage. Equidiameter dot junctions distributed across the surface of the cell offer an efficient alternative, with variations in dot diameter and in the spacing between dots giving the required variations in the ratio of junction area to total surface area. A simplified analysis for short-circuit current and other cell parameters, which enables cell design optimization, is presented. Experimental solar-cell performance results, as functions of different area ratios, are presented and compared with the model. It is shown that saturation current reduction is possible for achieving efficiencies as high as 18 percent in flat-plate terrestrial applications.
We describe a simple and passive nanosecond-long (ns-long) laser 'pulse-stretcher' using multiple optical ring-cavities. We present a model of the pulse-stretching process for an arbitrary number of optical ring-cavities. Using the model, we optimize the design of a pulse-stretcher for use in a spontaneous Raman scattering excitation system that avoids laser-induced plasma spark problems. From the optimized design, we then experimentally demonstrate and verify the model with a 3-cavity pulse-stretcher system that converts a 1000 mJ, 8.4 ns-long input laser pulse into an approximately 75 ns-long (FWHM) output laser pulse with a peak power reduction of 0.10X, and an 83% efficiency.
Modern computational and experimental tools for aerodynamics and propulsion applications have matured to a stage where they can provide substantial insight into engineering processes involving fluid flows, and can be fruitfully utilized to help improve the design of practical devices. In particular, rapid and continuous development in aerospace engineering demands that new design concepts be regularly proposed to meet goals for increased performance, robustness and safety while concurrently decreasing cost. To date, the majority of the effort in design optimization of fluid dynamics has relied on gradient-based search algorithms. Global optimization methods can utilize the information collected from various sources and by different tools. These methods offer multi-criterion optimization, handle the existence of multiple design points and trade-offs via insight into the entire design space, can easily perform tasks in parallel, and are often effective in filtering the noise intrinsic to numerical and experimental data. However, a successful application of the global optimization method needs to address issues related to data requirements with an increase in the number of design variables, and methods for predicting the model performance. In this article, we review recent progress made in establishing suitable global optimization techniques employing neural network and polynomial-based response surface methodologies. Issues addressed include techniques for construction of the response surface, design of experiment techniques for supplying information in an economical manner, optimization procedures and multi-level techniques, and assessment of relative performance between polynomials and neural networks. Examples drawn from wing aerodynamics, turbulent diffuser flows, gas-gas injectors, and supersonic turbines are employed to help demonstrate the issues involved in an engineering design context. Both the usefulness of the existing knowledge to aid current design practices and the need for future research are identified.
A procedure is outlined for determining the optimal design of friction dampers for high speed turbomachinery blading. The procedure includes: an integration of bench test results with finite element analysis and a single mode blade model to ensure accuracy of the analytical model and improve reliability of the friction damper design; an extension of the single mode blade model to predict the engine behavior of friction dampers; and a new way of viewing analytical and experimental results to determine optimal design parameters when the levels of excitation and damping in the system are unknown. Analysis and experiments are performed on a test disk in order to demonstrate and verify the accuracy of the design procedure.
The wind tunnel performance of a 10-percent thick helicopter rotor section design by numerical optimization is presented. The model was tested at Mach number from 0.2 to 0.84 with Reynolds number ranging from 1,900,000 at Mach 0.2 to 4,000,000 at Mach numbers above 0.5. The airfoil section exhibited maximum lift coefficients greater than 1.3 at Mach numbers below 0.45 and a drag divergence Mach number of 0.82 for lift coefficients near 0. A moderate 'drag creep' is observed at low lift coefficients for Mach numbers greater than 0.6.
This report summarizes the methods developed for the aerodynamic analysis and the shape optimization of the nozzle-afterbody section of a hypersonic vehicle. Initially, exhaust gases were assumed to be air. Internal-external flows around a single scramjet module were analyzed by solving the 3D Navier-Stokes equations. Then, exhaust gases were simulated by a cold mixture of Freon and Ar. Two different models were used to compute these multispecies flows as they mixed with the hypersonic airflow. Surface and off-surface properties were successfully compared with the experimental data. The Aerodynamic Design Optimization with Sensitivity analysis was then developed. Pre- and postoptimization sensitivity coefficients were derived and used in this quasi-analytical method. These coefficients were also used to predict inexpensively the flow field around a changed shape when the flow field of an unchanged shape was given. Starting with totally arbitrary initial afterbody shapes, independent computations were converged to the same optimum shape, which rendered the maximum axial thrust.
An experimental validation of the optimization-based integrated design methodology performed under the Controls-Structures Interaction (CSI) program for a class of flexible spacecraft is reviewed. The studies have been performed using an integrated design software tool which is under development at the NASA-Langley Research Center. It is analytically and experimentally demonstrated that integrated controls-structures design can yield designs which are substantially superior to those obtained through the traditional sequential approach.
This paper describes the first experimental validation of an optimization-based integrated controls-structures design methodology for a class of flexible space structures. The Controls-Structures-Interaction (CSI) Evolutionary Model, a laboratory test bed at Langley, is redesigned based on the integrated design methodology with two different dissipative control strategies. The redesigned structure is fabricated, assembled in the laboratory, and experimentally compared with the original test structure. Design guides are proposed and used in the integrated design process to ensure that the resulting structure can be fabricated. Experimental results indicate that the integrated design requires greater than 60 percent less average control power (by thruster actuators) than the conventional control-optimized design while maintaining the required line-of-sight performance, thereby confirming the analytical findings about the superiority of the integrated design methodology. Amenability of the integrated design structure to other control strategies is considered and evaluated analytically and experimentally. This work also demonstrates the capabilities of the Langley-developed design tool CSI DESIGN which provides a unified environment for structural and control design.
Two supersonic transport configurations designed by use of non-linear aerodynamic optimization methods are compared with a linearly designed baseline configuration. One optimized configuration, designated Ames 7-04, was designed at NASA Ames Research Center using an Euler flow solver, and the other, designated Boeing W27, was designed at Boeing using a full-potential method. The two optimized configurations and the baseline were tested in the NASA Langley Unitary Plan Supersonic Wind Tunnel to evaluate the non-linear design optimization methodologies. In addition, the experimental results are compared with computational predictions for each of the three configurations from the Enter flow solver, AIRPLANE. The computational and experimental results both indicate moderate to substantial performance gains for the optimized configurations over the baseline configuration. The computed performance changes with and without diverters and nacelles were in excellent agreement with experiment for all three models. Comparisons of the computational and experimental cruise drag increments for the optimized configurations relative to the baseline show excellent agreement for the model designed by the Euler method, but poorer comparisons were found for the configuration designed by the full-potential code.
Reduced gravity is used to carry out scientific investigations of droplet combustion. In earlier work a preliminary conceptual design had been developed for droplet burning experiments for Spacelab. Refinements of the earlier work with special consideration given to possible experiments for Mid-Deck Modules of the Space Shuttle is discussed. A re-evaluation of suitable experiments on droplet combustion is done to ascertain whether influences of reduced buoyancy on time-dependent processes of heat and mass transfer in the gas or in the liquid on extinction processes or on disruptive burning phenomena are best suited for further investigation. Components of the experimental apparatus, which include a droplet dispensing system, a droplet positioning system, a droplet ignition system and provision for recording, primarily photographically, the combustion of the individual droplet in a chamber having a controlled gas atmosphere, are studied to determine optimal approaches to the experimental design. Methods for data reduction and interpretation are being made more specific, particularly in the context of an objective to calculate overall gas-phase chemical-kinetic parameters for the combustion from observations of extinction conditions in different atmospheres.
Development of optimal design procedures by posing experimental design problem as finite decision problem
Bistable rollable booms are favorable when a low strain energy requirement for the coiled state is imposed and have more controllable deployment when compared to monostable booms. An inextensional analytical model describing the bending deformation mechanics of Collapsible Tubular Mast (CTM) booms was used to determine how design variables induce bistability, or the existence of two strain energy wells in the rolled-up and unrolled states. The effects of varying lamina material, laminate layup, and shell arc geometries between different inner and outer shell segments on the second strain energy well and stiffness properties were determined for boom cross-sections formed by circular segments. The full design space for two-walled composite CTM booms was explored to evaluate the validity of the developed analytical model. Optimized CTM boom designs were experimentally characterized for comparisons against model results. The model under-predicted the stable coiled diameter of the co-cured two-walled booms by up to 8.9% and 23.4% for the individual thin shells wrapped alone.