Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “design challenges”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 379 records · Page 21

A Comparison of Metallic, Composite and Nanocomposite Optimal Transonic Transport Wings

Current and future composite material technologies have the potential to greatly improve the performance of large transport aircraft. However, the coupling between aerodynamics and structures makes it challenging to design optimal flexible wings, and the transonic flight regime requires high fidelity computational models. We address these challenges by solving a series of high-fidelity aerostructural optimization problems that explore the design space for the wing of a large transport aircraft. We consider three different materials: aluminum, carbon-fiber reinforced composites and an hypothetical composite based on carbon nanotubes. The design variables consist of both aerodynamic shape (including span), structural sizing, and ply angle fractions in the case of composites. Pareto fronts with respect to structural weight and fuel burn are generated. The wing performance in each case is optimized subject to stress and buckling constraints. We found that composite wings consistently resulted in lower fuel burn and lower structural weight, and that the carbon nanotube composite did not yield the increase in performance one would expect from a material with such outstanding properties. This indicates that there might be diminishing returns when it comes to the application of advanced materials to wing design, requiring further investigation.

Kennedy, Graeme J.↗

Design and test of a small two stage counter-rotating turbine for rocket engine application

The aerodynamic design and rig test evaluation of a small counter-rotating turbine system is described. The technology represented by this turbine is being developed for application in an advanced upper stage rocket engine turbopump. This engine will employ an oxygen/hydrogen expander cycle and achieve high performance through efficient combustion, high combustion pressure, and high area ratio exhaust nozzle expansion. Engine performance goals require that the turbopump drive turbines achieve high efficiency at low gas flow rates. The low flow rates result in very small airfoil diameter, height and chord. The high efficiency and small size requirements present a challenging turbine design problem. The unconventional approach employed to meet this challenge is described, along with the detailed design process and resulting airfoil configurations. The method and results of full scale aerodynamic performance evaluation testing of both one and two stage configurations, as well as operation without the secondary stage stator are presented. The overall results of this effort illustrate that advanced aerodynamic design tools and hardware fabrication techniques have provided improved capability to produce small high performance turbines for advanced rocket engines.

Huber, F. W.↗

Noise-Reduction Benefits Analyzed for Over-the-Wing-Mounted Advanced Turbofan Engines

As we look to the future, increasingly stringent civilian aviation noise regulations will require the design and manufacture of extremely quiet commercial aircraft. Also, the large fan diameters of modern engines with increasingly higher bypass ratios pose significant packaging and aircraft installation challenges. One design approach that addresses both of these challenges is to mount the engines above the wing. In addition to allowing the performance trend towards large diameters and high bypass ratio cycles to continue, this approach allows the wing to shield much of the engine noise from people on the ground. The Propulsion Systems Analysis Office at the NASA Glenn Research Center at Lewis Field conducted independent analytical research to estimate the noise reduction potential of mounting advanced turbofan engines above the wing. Certification noise predictions were made for a notional long-haul commercial quadjet transport. A large quad was chosen because, even under current regulations, such aircraft sometimes experience difficulty in complying with certification noise requirements with a substantial margin. Also, because of its long wing chords, a large airplane would receive the greatest advantage of any noise-shielding benefit.

Berton, Jeffrey J.↗

Material Properties Analysis of Structural Members in Pumpkin Balloons

The efficient design, service-life qualification, and reliability predictions for lightweight aerospace structures require careful mechanical properties analysis of candidate structural materials. The demand for high-quality laboratory data is particularly acute when the candidate material or the structural design has little history. The pumpkin-shaped super-pressure balloon presents both challenges. Its design utilizes load members (tendons) extending from apex to base around the gas envelope to achieve a lightweight structure. The candidate tendon material is highly weight-efficient braided HM cord. Previous mechanical properties studies of Zylon have focused on fiber and yarn, and industrial use of the material in tensile applications is limited. For high-performance polymers, a carefully plamed and executed properties analysis scheme is required to ensure the data are relevant to the desired application. Because no directly-applicable testing standard was available, a protocol was developed based on guidelines fiom professional and industry organizations. Due to the liquid-crystalline nature of the polymer, the cord is very stiff, creeps very little, and does not yield. Therefore, the key material property for this application is the breaking strength. The pretension load and gauge length were found to have negligible effect on the measured breaking strength over the ranges investigated. Strain rate was found to have no effect on breaking strength, within the range of rates suggested by the standards organizations. However, at the lower rate more similar to ULDB operations, the strength was reduced. The breaking strength increased when the experiment temperature was decreased from ambient to 183K which is the lowest temperature ULDB is expected to experience. The measured strength under all test conditions was well below that resulting from direct scale-up of fiber strength based on the manufacturers data. This expected result is due to the effects of the braiding process and material ageing.

Sterling, W. J.↗

High-Altitude ADS-B Flight Tests on a NASA ER-2 Research Airplane

Researchers at the National Aeronautics and Space Administration (NASA) Armstrong Flight Research Center (Edwards, California); the Federal Aviation Administration (FAA); and Regulus Group, LLC (Atlantic City, New Jersey) collaborated for the flight-test demonstration of an Automatic Dependent Surveillance-Broadcast (ADS-B) system equipped on a high-altitude Earth Resources-2 (ER-2) research airplane. The unique ER-2 airplane is a NASA-owned and operated airborne science version of the United States Air Force / Lockheed Martin Aeronautics (Bethesda, Maryland) U-2S airplane. The FAA has mandated that by the year 2020, aircraft operating within certain sections of the United States National Airspace system be equipped with ADS-B Out technology; the research presented in this paper is the first to show how the NASA ADS-B architecture satisfies the mandate for a unique high-altitude aircraft. An exceptional military aircraft design, security protocols, and the performance envelope of the ER-2 airplane made the avionics integration remarkably challenging. The design required the ADS-B avionics to survive the harsh flight environment of the ER-2 airplane. The most prominent challenge was the functional integration of modern civilian avionics into federated military legacy avionics. Flight-test objectives were to certify an ADS-B Out (1090ES) passive surveillance integrated with a Traffic Alert and Collision Avoidance System (TCAS) I active surveillance system on an ER-2 platform for high-altitude cruise operations. In April 2022, NASA conducted three flights at Edwards Air Force Base (Edwards, California) - each greater than one-hour flight reaching altitudes above 60,000 ft.

ADS-B↗

Expert systems and their use in augmenting design optimization

The challenging requirements that are evolving for future aircraft demand that each design be optimally integrated, for the penalties imposed by nonoptimal performance are significant. Classic numerical optimization algorithms have been and will continue to be important tools for aircraft designers. These methods are, however, limited to certain categories of aircraft design variables, leaving the remainder to be determined by the user. A method that makes use of knowledge-based expert systems offers the potential for aiding the conceptual design process in a way that is similar to that of numerical optimization, except that it would address discrete, discontinuous, abstract, or any other unoptimized aspect of vehicle design and integration. Other unique capabilities such as automatic discovery and learning in design may also be achievable in the near term. This paper discusses current practice in conceptual aircraft design and knowledge-based systems, and how knowledge-based systems can be used in conceptual design.

Kidwell, G. H.↗

Noise Reduction Potential of Large, Over-the-Wing Mounted, Advanced Turbofan Engines

As we look to the future, increasingly stringent civilian aviation noise regulations will require the design and manufacture of extremely quiet commercial aircraft. Indeed, the noise goal for NASA's Aeronautics Enterprise calls for technologies that will help to provide a 20 EPNdB reduction relative to today's levels by the year 2022. Further, the large fan diameters of modem, increasingly higher bypass ratio engines pose a significant packaging and aircraft installation challenge. One design approach that addresses both of these challenges is to mount the engines above the wing. In addition to allowing the performance trend towards large, ultra high bypass ratio cycles to continue, this over-the-wing design is believed to offer noise shielding benefits to observers on the ground. This paper describes the analytical certification noise predictions of a notional, long haul, commercial quadjet transport with advanced, high bypass engines mounted above the wing.

Berton, Jeffrey J.↗

2nd International Planetary Probe Workshop

Included are presentations from the 2nd International Planetary Probe Workshop. The purpose of the second workshop was to continue to unite the community of planetary scientists, spacecraft engineers and mission designers and planners; whose expertise, experience and interests are in the areas of entry probe trajectory and attitude determination, and the aerodynamics/aerothermodynamics of planetary entry vehicles. Mars lander missions and the first probe mission to Titan made 2004 an exciting year for planetary exploration. The Workshop addressed entry probe science, engineering challenges, mission design and instruments, along with the challenges of reconstruction of the entry, descent and landing or the aerocapture phases. Topics addressed included methods, technologies, and algorithms currently employed; techniques and results from the rich history of entry probe science such as PAET, Venera/Vega, Pioneer Venus, Viking, Galileo, Mars Pathfinder and Mars MER; upcoming missions such as the imminent entry of Huygens and future Mars entry probes; and new and novel instrumentation and methodologies.

Venkatapathy, Ethiraj↗

The Challenger Tradgedy was Caused by an Apollo Mistake, Terminating Risk Analysis

NASA’s attitude toward risk changed drastically between the Apollo and Space Shuttle design. [1]Apollo engineers were seriously alarmed about riskbecause of the fatal Apollo 1 fire and the fact that the estimated probability of another fatal accident was extremely high. The predictions were so appalling thatmanagement terminated risk analysis to avoid public apprehension. Because risk analysis was not done, the Space Shuttle design accepted excessively high andunknown risk. The immediate cause of the Challengertragedy was the mistaken decision to launch in coldweather that impaired the O-ring seals, but the fundamental cause was the high risk of the shuttle design. Before Challenger, management asserted that the probability of a fatal accident was 1 in 100,000.Probabilistic Risk Analysis (PRA) found a roughly 1 in 100 chance of a shuttle failure.

Harry W Jones↗

Autonomy Software: V&V Challenges and Characteristics

The successful operation of unmanned air vehicles requires software with a high degree of autonomy. Only if high level functions can be carried out without human control and intervention, complex missions in a changing and potentially unknown environment can be carried out successfully. Autonomy software is highly mission and safety critical: failures, caused by flaws in the software cannot only jeopardize the mission, but could also endanger human life (e.g., a crash of an UAV in a densely populated area). Due to its large size, high complexity, and use of specialized algorithms (planner, constraint-solver, etc.), autonomy software poses specific challenges for its verification, validation, and certification. -- - we have carried out a survey among researchers aid scientists at NASA to study these issues. In this paper, we will present major results of this study, discussing the broad spectrum. of notions and characteristics of autonomy software and its challenges for design and development. A main focus of this survey was to evaluate verification and validation (V&V) issues and challenges, compared to the development of "traditional" safety-critical software. We will discuss important issues in V&V of autonomous software and advanced V&V tools which can help to mitigate software risks. Results of this survey will help to identify and understand safety concerns in autonomy software and will lead to improved strategies for mitigation of these risks.

Schumann, Johann↗

Ares I-X Flight Test Development Challenges and Success Factors

The NASA Constellation Program's Ares I-X rocket launched successfully on October 28, 2009 collecting valuable data and providing risk reduction for the Ares I project. The Ares I-X mission was formulated and implemented in less than four years commencing with the Exploration Systems Architecture Study in 2005. The test configuration was founded upon assets and processes from other rocket programs including Space Shuttle, Atlas, and Peacekeeper. For example, the test vehicle's propulsion element was a Shuttle Solid Rocket Motor. The Ares I-X rocket comprised a motor assembly, mass and outer mold line simulators of the Ares I Upper Stage, Orion Spacecraft and Launch Abort System, a roll control system, avionics, and other miscellaneous components. The vehicle was 327 feet tall and weighed approximately 1,800,000 pounds. During flight the rocket reached a maximum speed of Mach 4.8 and an altitude of 150,000 feet. The vehicle demonstrated staging at 130,000 feet, tested parachutes for recovery of the motor, and utilized approximately 900 sensors for data collection. Developing a new launch system and preparing for a safe flight presented many challenges. Specific challenges included designing a system to withstand the environments, manufacturing large structures, and re-qualifying heritage hardware. These and other challenges, if not mitigated, may have resulted in test cancellation. Ares I-X succeeded because the mission was founded on carefully derived objectives, led by decisive and flexible management, implemented by an exceptionally talented and dedicated workforce, and supported by a thorough independent review team. Other major success factors include the use of proven heritage hardware, a robust System Integration Laboratory, multi-NASA center and contractor team, concurrent operations, efficient vehicle assembly, effective risk management, and decentralized element development with a centralized control board. Ares I-X was a technically complex test that required creative thinking, risk taking, and a passion to succeed.

Askins, Bruce↗

Exploration Portable Life Support System Hatch Component Design

The design for the Exploration Extravehicular Mobility Unit (xEMU) is continuously being developed and many previous gaps in technologies have begun initial development. Various Exploration Portable Life Support System (xPLSS) Hatch components had been at a stall in technology development for many years including the Feedwater Supply Assembly, Trace Contaminant Control System, and the thermal loop filters. The challenging requirements and initial design of these components were previously discussed in “Exploration Portable Life Support System Hatch Component Design Challenges and Progress”. NASA has plans to go back to the Moon. The development of each of these components is relevant not only to the xEMU, but also to the International Space Station, Gateway, and commercial space businesses. As the xPLSS is being designed, built, integrated, and tested at the NASA Johnson Space Center, technology solutions will have a direct incorporation path as the xPLSS is matured to meet design and performance goals. This is a follow on paper to discuss the initial implementation of the hatch component designs, changes due to existing challenges, and performance results of these components as the xEMU project completes the first phase of towards flight, known as Design Verification Test (DVT).

Kristina Todd↗

Designing Non-Pneumatic, Structural Tires for Space: Challenges and Solutions for a Difficult Application

Design and development of Shape Memory Alloy (SMA) Tires is a difficult and challenging problem. A “build and test” approach isn’t practical due to both the expense and time associated with taking such an approach. The multiple iterations that would be required to close requirements space for a space flight hardware program makes this approach infeasible. Hence, details regarding GRC’s SMA modeling approach to solving this challenging problem will be highlighted and used to showcase the power associated with leveraging an SMA modeling framework during design.

Shape Memory Alloys (SMA)↗

Structural Design Exploration of an Electric Powered Multi-Propulsor Wing Configuration

Advancements in aircraft electric propulsion may enable an expanded operational envelope for electrically powered vehicles compared to their internal combustion engine counterparts. High aspect ratio wings provide additional lift and drag reduction for a proposed multi-propulsor design, however, the challenge is to reduce the weight of wing structures while maintaining adequate structural and aeroelastic margins. Design exploration using a conventional design-and-build philosophy coupled with a finite element method (FEM)-based design of experiments (DOE) strategy are presented to examine high aspect ratio wing structures that have spanwise distributed electric motors. Multiple leading-edge-mounted engine masses presented a challenge to design a wing within acceptable limits for dynamic and aeroelastic stability. Because the first four primary bending eigenmodes of the proposed wing structure are very sensitive to outboard motor placement, safety-of-flight requirements drove the need for multiple spars, rib attachments, and outboard structural reinforcements in the design. Global aeroelasticity became an increasingly important design constraint during the on-going design process, with outboard motor pod flutter ultimately becoming a primary design constraint. Designers successively generated models to examine stress, dynamics, and aeroelasticity concurrently. This research specifically addressed satisfying multi-disciplinary design criteria to generate fluid-structure interaction solution sets, and produced high aspect ratio primary structure designs for the NASA Scalable Convergent Electric Propulsion Technology and Operations Research (SCEPTOR) project in the Aeronautic Research Mission Directorate at NASA. In this paper, a dynamics-driven, quasi-inverse design methodology is presented to address aerodynamic performance goals and structural challenges encountered for the SCEPTOR demonstrator vehicle. These results are compared with a traditional computer aided design based approach.

Moore, James B.↗

High Power Hall Thrusters

The development of Hall thrusters with powers ranging from tens of kilowatts to in excess of one hundred kilowatts is considered based on renewed interest in high power. high thrust electric propulsion applications. An approach to develop such thrusters based on previous experience is discussed. It is shown that the previous experimental data taken with thrusters of 10 kW input power and less can be used. Potential mass savings due to the design of high power Hall thrusters are discussed. Both xenon and alternate thruster propellant are considered, as are technological issues that will challenge the design of high power Hall thrusters. Finally, the implications of such a development effort with regard to ground testing and spacecraft intecrati'on issues are discussed.

Jankovsky, Robert↗

An Automated Method to Compute Orbital Re-Entry Trajectories with Heating Constraints

Determining how to properly manipulate the controls of a re-entering re-usable launch vehicle (RLV) so that it is able to safely return to Earth and land involves the solution of a two-point boundary value problem (TPBVP). This problem, which can be quite difficult, is traditionally solved on the ground prior to flight. If necessary, a nearly unlimited amount of time is available to find the "best" solution using a variety of trajectory design and optimization tools. The role of entry guidance during flight is to follow the pre-determined reference solution while correcting for any errors encountered along the way. This guidance method is both highly reliable and very efficient in terms of onboard computer resources. There is a growing interest in a style of entry guidance that places the responsibility of solving the TPBVP in the actual entry guidance flight software. Here there is very limited computer time. The powerful, but finicky, mathematical tools used by trajectory designers on the ground cannot in general be made to do the job. Nonconvergence or slow convergence can result in disaster. The challenges of designing such an algorithm are numerous and difficult. Yet the payoff (in the form of decreased operational costs and increased safety) can be substantial. This paper presents an algorithm that incorporates features of both types of guidance strategies. It takes an initial RLV orbital re-entry state and finds a trajectory that will safely transport the vehicle to a Terminal Area Energy Management (TAEM) region. During actual flight, the computed trajectory is used as the reference to be flown by a more traditional guidance method.

Zimmerman, Curtis↗

Technology Transfer Challenges: A Case Study of User-Centered Design in NASA's Systems Engineering Culture

The Upper Stage (US) section of the National Aeronautics and Space Administration's (NASA) Ares I rocket will require internal access platforms for maintenance tasks performed by humans inside the vehicle. Tasks will occur during expensive critical path operations at Kennedy Space Center (KSC) including vehicle stacking and launch preparation activities. Platforms must be translated through a small human access hatch, installed in an enclosed worksite environment, support the weight of ground operators and be removed before flight - and their design must minimize additional vehicle mass at attachment points. This paper describes the application of a user-centered conceptual design process and the unique challenges encountered within NASA's systems engineering culture focused on requirements and "heritage hardware". The NASA design team at Marshall Space Flight Center (MSFC) initiated the user-centered design process by studying heritage internal access kits and proposing new design concepts during brainstorming sessions. Simultaneously, they partnered with the Technology Transfer/Innovative Partnerships Program to research inflatable structures and dynamic scaffolding solutions that could enable ground operator access. While this creative, technology-oriented exploration was encouraged by upper management, some design stakeholders consistently opposed ideas utilizing novel, untested equipment. Subsequent collaboration with an engineering consulting firm improved the technical credibility of several options, however, there was continued resistance from team members focused on meeting system requirements with pre-certified hardware. After a six-month idea-generating phase, an intensive six-week effort produced viable design concepts that justified additional vehicle mass while optimizing the human factors of platform installation and use. Although these selected final concepts closely resemble heritage internal access platforms, challenges from the application of the user-centered process provided valuable lessons for improving future collaborative conceptual design efforts.

Quick, Jason↗

Multidisciplinary Design Optimization of Low-Boom Supersonic Aircraft with Mission Constraints

Design of low-boom supersonic aircraft is heavily dictated by aircraft volume and lift distributions. These unique design characteristics make it a challenge to enforce mission requirements (such as static margins and trim requirements) during design optimization. This low-boom design challenge is resolved by using reversed equivalent area targets for low-fidelity low-boom design and a decomposition method for multidisciplinary design optimization(MDO).The corresponding low-boom MDO problem includes aircraft mission constraints for cruise ranges, cruise speeds, trim margin for low-boom cruise, static margins for takeoff/cruise/landing, tail rotation angles for trim at takeoff/landing, takeoff/landing field lengths, and approach velocity, as well as volume constraints for cabin and main landing gear packaging. The decomposition method is developed to optimally resolve the conflicts between the low-boom design objective and other design constraints. The decomposition method is successfully applied to design a low-boom supersonic configuration that carries 40 passengers, has low-boom cruise of Mach 1.6 with range ≥ 2,500 nm, and can also cruise at Mach 1.8 with range ≥ 3,600 nm. The generated configuration satisfies all specified mission constraints and has the potential to achieve a low-boom ground noise level below 75 PLdB.

Wu Li↗