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The status, problems, and requirements in the technical disciplines related to the design of composite structures are discussed. Papers are presented in the areas of applications in design; concepts in design; and methodology in design.
This conference publication contains the proceedings of the Eighth DoD/NASA/FAA Conference on Fibrous Composites in Structural Design held in Norfolk, Virginia during November 28-30, 1989. Presentations were made in the following areas of composite structural design: perspectives in composites; applications in design; concepts in design; methodology in design, and reliability in design.
The National Aero-Space Plane (NASP) program has recently entered a new phase of the program known as Phase 2D. During this period, five aerospace companies and the Government have formed a National Team. This team has focused on developing a single experimental (X-30) vehicle design and are pursuing a technology validation and demonstration program to prove out the design concepts and design tools. This paper presents an overview of the Phase 2D round testing being conducted to validate the X-30 design and to demonstrate the critical technologies needed to build and fly a research vehicle during Phase 3 of the program. The Phase 2D exit criteria are discussed to identify how they provide top-level guidance for developing the ground test program. An overview of major test facility modifications being performed in support of the test program is also presented. Emphasis is placed on propulsion and structures testing since these are felt to be the primary areas requiring technologies beyond the current state-of-the-art. Also discussed is the use of uncertainty analysis as a method to account for uncertainties in test data. In addition, this paper addresses the use of these uncertainties to develop qualitative indicators of how well the design and technology developed during Phase 2 have matured.
America at the Threshold: Report of the Synthesis Group on America's Space Exploration Initiative (the 'Synthesis Report,' sometimes called the Stafford Report after its astronaut chair, published in 1991) recommended that NASA explore what it called four 'architectures,' i.e., four different scenarios for habitation on Mars. The Advanced Design Program in Space Architecture at the University of Wisconsin-Milwaukee supported this report and two of its scenarios--'Architecture 1' and 'Architecture 4'--during the spring of 1992. This report investigates the implications of different mission scenarios, the Martian environment, supporting technologies, and especially human factors and environment-behavior considerations for the design of the first permanent Martian base. The report is comprised of sections on mission analysis, implications of the Martian atmosphere and geologic environment, development of habitability design requirements based on environment-behavior and human factors research, and a full design proposed (concept design and design development) for the first permanent Martian base and habitat. The design is presented in terms of a base site plan, master plan based on a Mars direct scenario phased through IOC, and design development details of a complete Martian habitat for 18 crew members including all laboratory, mission control, and crew support spaces.
Advances in modeling and simulation, new finite element software, modeling engines and powerful computers are providing opportunities to interrogate designs in a very different manner and in a more detailed approach than ever before. Margins of safety are also often evaluated using local stresses for various design concepts and design parameters quickly once analysis models are defined and developed. This paper suggests that not all the negative margins of safety evaluated are real. The structural areas where negative margins are frequently encountered are often near stress concentrations, point loads and load discontinuities, near locations of stress singularities, in areas having large gradients but with insufficient mesh density, in areas with modeling issues and modeling errors, and in areas with connections and interfaces, in two-dimensional (2D) and three-dimensional (3D) transitions, bolts and bolt modeling, and boundary conditions. Now, more than ever, structural analysts need to examine and interrogate their analysis results and perform basic sanity checks to determine if these negative margins are real.
The human short term memory span and working capacity is limited to three to five items, especially if they are organized complex “chunks” of information. The impression of complexity occurs when a system is simply difficult to understand, where there is no apparent pattern to predict its behavior. Hierarchical systems design can reduce perceived complexity and increase the amount of information that can be managed. The SCM was developed to measure complexity and help compare proposed overall system architectures before detailed design information is available. The SCM is defined as the sum of the number of major nodes, N, in the system block diagram plus the number of one-way interactions, I, between the nodes. SCM = N + I. SCM’s are easily determined by direct inspection of high-level block diagrams of life support systems. Axiomatic design develops a hierarchy of subsystem requirements and designs together in a top-down, back-and-forth process. A coupling matrix is used to control the relationships between the subsystem functions and design concepts. Axiomatic design can improve system design by decoupling requirements and designs. Axiomatic design was applied to the planning of a closed life support system, similar to that used on the International Space Station. A materially open as opposed to a closed system design was created by removing the interconnections required to close the system. The open system had the same number of designed subsystems as the closed system, but it had many fewer interconnections and its SCM was lower by about half. The costs were estimated and the MTBF (Mean Time Before Failure) tabulated for open and closed space life support systems. The estimated costs were linearly proportional to SCM for the wide variations of SCM in life support, but small differences may not be significant. The flight and preflight MTBF’s both declined exponentially with increasing MTBF, faster than MTBF-2, even though the preflight estimated MTBF’s were about ten times higher than the flight MTBF’s.
Advances in modeling and simulation, new finite element software, modeling engines and powerful computers are providing opportunities to interrogate designs in a very different manner and in a more detailed approach than ever before. Margins of safety are also often evaluated using local stresses for various design concepts and design parameters quickly once analysis models are defined and developed. This paper suggests that not all the negative margins of safety evaluated are real. The structural areas where negative margins are frequently encountered are often near stress concentrations, point loads and load discontinuities, near locations of stress singularities, in areas having large gradients but with insufficient mesh density, in areas with modeling issues and modeling errors, and in areas with connections and interfaces, in two-dimensional (2D) and three-dimensional (3D) transitions, bolts and bolt modeling, and boundary conditions. Now, more than ever, structural analysts need to examine and interrogate their analysis results and perform basic sanity checks to determine if these negative margins are real.
An ejector design concept for V/STOL aircraft, featuring a double-delta configuration with two large chordwise ejector slots adjacent to the fuselage side and a tailplane or canard for longitudinal control is examined. Large scale model tests of the concept have shown that ejector systems are capable of significant thrust augmentation at realistic supply pressures and temperatures, so that power plant size and weight can be reduced accordingly. A thrust augmentation of at least 1.75 can be achieved for the isolated ejector, not making allowance for duct and nozzle losses. Substantial reductions in velocity, temperature and noise of the lifting jet are assured due to mixing within the ejector - this lessens the severity of ground erosion and the thrust loss associated with reingestion. Consideration is also given to the effect of ground proximity, longitudinal aerodynamic characteristics, transition performance, and lateral stability.
The results of a simulation study of an alternative design concept for an automatic landing control system are presented. The alternative design concept for an automatic landing control system is described. The design concept is the total aircraft flight control system (TAFCOS). TAFCOS is an open loop, feed forward system that commands the proper instantaneous thrust, angle of attack, and roll angle to achieve the forces required to follow the desired trajector. These dynamic trim conditions are determined by an inversion of the aircraft nonlinear force characteristics. The concept was applied to an A-7E aircraft approaching an aircraft carrier. The implementation details with an airborne digital computer are discussed. The automatic carrier landing situation is described. The simulation results are presented for a carrier approach with atmospheric disturbances, an approach with no disturbances, and for tailwind and headwind gusts.
Solar electric propulsion (SEP) mission architectures are applicable to a wide range NASA missions including the robotic exploration of the outer planets in the next decade and the human exploration of Mars within the next 2 decades. SEP enables architectures that are very mass efficient with reasonable power levels (1-MW class) aerobrake and cryogenic upper-stage transportation technologies are utilized. In this architecture, the efficient SEP stage transfers the payload from low Earth orbit (LEO) High Energy Elliptical Parking Orbit (HEEPO) within a period of 6 to 12 months. highthrust, cryogenic upper stage and payload then separate from the SEP vehicle for injection to the planetary target, allowing for fast heliocentric trip times. This mission architecture offers a potential reduction in mass to LEO in comparison to alternative all-chemical nuclear propulsion schemes. Mass reductions may allow launch vehicle downsizing enable missions that would have been grounded because of cost constraints. The preceding figure illustrates a conceptual SEP stage design for a human Mars mission. Researchers at the NASA Glenn Research Center at Lewis Field designed conceptual SEP vehicle, conceived the mission architecture to use this vehicle, and analyzed the vehicle s performance. This SEP stage has a dry mass of 35 metric tons (MT), 40 MT of xenon propellant, and a photovoltaic array that spans 110 m, providing power to a cluster of eight 100-kW Hall thrusters. The stage can transfer an 80-MT payload and upper stage to the desired HEEPO. Preliminary packaging studies show this space-station-class SEP vehicle meets the proposed "Magnum" launch vehicle and volume requirements with considerable margin. An SEP vehicle for outer planetary missions, such as the Europa Mapper Mission, would be dramatically smaller than human Mars mission SEP stage. In this mission architecture, the SEP power system with the payload to provide spacecraft power throughout the mission. Several photovoltaic array design concepts were considered for the SEP vehicle power system for the human mission to Mars. These include a space station derivative, a SCARLET (Solar Concentrator Arrays with Refractive Linear Element Technology) derivative, and a hybrid inflatable-deployable thin polymer membrane array with thin-film solar cells (as shown in the concept illustration). This concept is based on a design developed for the Next Generation Space Telescope Sun shield. The array is divided into 16 independent electrical sections with 500-V, negative-grounded solar cell strings. The power system employs a channelized, 500-Vdc power management and distribution (PMAD) architecture with lithium ion batteries for energy storage for vehicle and payload secondary loads (the high-power Hall thrusters do not operate in eclipse periods). The 500-V PMAD voltage permits "direct-drive" thruster operation, greatly reducing the power processing unit size, complexity, and power loss. Similar power system architecture, designs, and technology are assumed for the Europa Mapper Mission SEP vehicle. The primary exceptions are that the photovoltaic array is assumed to consist of two rectangular wings and that the power system rating is 15 kW in Earth orbit and 200 W at Europa. To size the SEP vehicle power system, a dedicated Fortran code was developed to predict detailed power system performance, mass, and thermal control requirements. This code also modeled all the relevant Earth orbit environments; that is, the particulate radiation, plasma, meteoroids and debris, ultraviolet radiation, contamination, and thermal conditions. Analysis results for the Human Mars Mission SEP vehicle show a power system mass of 9-MT and photovoltaic array area of 5800-square meters for the thin-membrane design concept with CuInS2 thin-film cells. Power processing unit input power for a thin-membrane array design with three-junction, amorphous SiGe solar cells is shown in the graph. Power falls off rapidly inhe first weeks of the mission because of light-induced (Staebler-Wronksi) solar cell losses. During the next 200 days, power decreases steadily as the SEP stage spirals through the proton belts and sustains the bulk of the mission radiation damage. Once the vehicle apogee is above approximately four Earth radii, little additional degradation is incurred. From 400 to 800 days, a 1100-km "parking" orbit is maintained to await the next payload transfer opportunity. This orbit is below the main proton belt, and thus, little radiation dose is accumulated during this time period. During the second LEO-to-HEEPO transfer, power degrades somewhat further, but power requirements are still met. In comparison, the Europa Mapper SEP vehicle power system had a mass of 150 kg and a thin membrane array area of 100 square meters.
The objectives are to experimentally confirm several advanced design concepts on the Magnetic Suspension and Balance Systems (MSBS). The advanced design concepts were identified as potential improvements by Madison Magnetics, Inc. (MMI) during 1984 and 1985 studies of an MSBS utilizing 14 external superconductive coils and a superconductive solenoid in an airplane test model suspended in a wind tunnel. This study confirmed several advanced design concepts on magnetic suspension and balance systems. The 1989 MSBS redesign is based on the results of these experiments. Savings of up to 30 percent in supporting magnet ampere meters and 50 percent in energy stored over the 1985 design were achieved.
The development and evaluation of a design concept for the cooled structures assembly for the Scramjet engine is discussed. Development concepts for engine subsystems and design concepts for the aircraft/engine interface are included. A thermal protection system was defined which makes it possible to attain a life of 100 hr and 1000 cycles, the specified goal. The coolant equivalence ratio at the Mach 10 maximum thermal loading condition is 0.6, indicating a capacity for airframe cooling. The mechanical design is feasible for manufacture using conventional materials. For the cooled structures in a six module engine, the mass per unit capture area is 1256 kg/sq m. The total mass of a six module engine assembly including the fuel system is 1502 kg.
A Mars Ascent Vehicle (MAV) would be one component of potential Mars Sample Return (MSR) and would have to launch from the surface of Mars into orbit about Mars with a soil sample. A MAV is a small lightweight rocket that must survive various environmental conditions, including powered ascent through the Martian atmosphere. A concept for the MAV system design includes a launch tube mounted on top of a mobile rover or a stationary lander. The launch tube must thermally insulate the MAV on the surface of Mars, and then guide the MAV during the initial portion of the launch. A mechanical erector system is also necessary for moving the MAV and launch tube from a stowed configuration to a launch configuration. The launch system would have to perform these tasks while also meeting many design constraints. This paper is a systems engineering perspective that will examine the current development of the launch system including design concepts, design trades, driving issues, and analyses performed. Design trades include different launch configurations that would prevent rover or lander tip-over, as well as re-contact between the MAV and the launch tube. Additional trades include options for guiding the MAV out of the launch tube, whether using launch rails or sabots, and finding a reliable but simple mechanical erector system. Analyses include investigating the impact of ignition overpressure based on launch configuration, launch loads and sensitivities to the launch system design, and Entry, Descent and Landing loads. The key considerations for these design trades are overall system mass, size, and reliability.
Compass Team was tasked by the RPS Project at the NASA Glenn Research Center (GRC) to create an independent concept design for a spacecraft (S/C) utilizing low power radioisotope power. A list of candidate missions enabled by milliwatt class radioisotope power was evaluated and thus resulted in the selection of a Mars polar region seismology network of four hard landers. A science rational and science operations plan was developed to establish mission design requirements and S/C subsystem concept designs described herein.
Design concepts for high temperature flush mounted Space Shuttle Orbiter antenna systems are discussed. The design concepts include antenna systems for VHF, L-band, S-band, C-band and Ku-band frequencies. The S-band antenna system design was completed and test hardware fabricated. It was then subjected to electrical and thermal testing to establish design requirements and determine reuse capabilities. The thermal tests consisted of applying ten high temperature cycles simulating the Orbiter entry heating environment in an arc tunnel plasma facility and observing the temperature distributions. Radiation pattern and impedance measurements before and after high temperature exposure were used to evaluated the antenna systems performance. Alternate window design concepts are considered. Layout drawings, supported by thermal and strength analyses, are given for each of the antenna system designs. The results of the electrical and thermal testing of the S-band antenna system are given.
The use of active pogo suppressors on the space shuttle was qualitatively investigated. Suppressor design concepts and the effectiveness of these designs in maintaining the stability of the shuttle vehicle were the primary concerns. Suppressor design concepts were developed by means of a series of parametric stability analyses. These two designs together with two designs provided by NASA were evaluated in detail for control effectiveness, performance relative to a passive suppression device, sensitivity of performance to feedback error, suppressor volume flow requirements, and suppressor development requirements. An active device at the high pressure oxidizer pump inlet was shown to provide a simple and effective design that is insensitive to error in the feedback signal. The sizing of an active suppressor was demonstrated to be dependent upon knowledge of the dynamic characteristics of the system.
As part of a program to reduce wind turbine costs, an evaluation was conducted of a laminated wood composite blade for the Mod-OA 200 kW wind turbine. The effort included the design and fabrication concept for the blade, together with cost and load analyses. The blade structure is composed of laminated Douglas fir veneers for the primary spar and nose sections, and honeycomb cored plywood panels for the trailing edges sections. The attachment of the wood blade to the rotor hub was through load takeoff studs bonded into the blade root. Tests were conducted on specimens of the key structural components to verify the feasibility of the concept. It is concluded that the proposed wood composite blade design and fabrication concept is suitable for Mod-OA size turbines (125-ft diameter rotor) at a cost that is very competitive with other methods of manufacture.
The work reported here is an overview and snapshot of a project to develop practical model checking tools for in-the-loop verification of NASA s mission-critical, multithreaded programs in Java and C++. Our strategy is to develop and evaluate both a design concept that enables the application of model checking technology to C++ and Java, and a model checking toolset for C++ and Java. The design concept and the associated model checking toolset is called Propel. It builds upon the Java PathFinder (JPF) tool, an explicit state model checker for Java applications developed by the Automated Software Engineering group at NASA Ames Research Center. The design concept that we are developing is Design for Verification (D4V). This is an adaption of existing best design practices that has the desired side-effect of enhancing verifiability by improving modularity and decreasing accidental complexity. D4V, we believe, enhances the applicability of a variety of V&V approaches; we are developing the concept in the context of model checking. The model checking toolset, Propel, is based on extending JPF to handle C++. Our principal tasks in developing the toolset are to build a translator from C++ to Java, productize JPF, and evaluate the toolset in the context of D4V. Through all these tasks we are testing Propel capabilities on customer applications.