The Application of High Density Electronic Packaging for Spacecraft Cost and Mass Reduction
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spacecraft electyronic systems system performance ↗
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Reduction in Computational Cost of Progressive Failure Analysis of Composite Structures
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Computational Cost↗
Slicing of Silicon into Sheet Material. Silicon Sheet Growth Development for the Large Area Silicon Sheet Task of the Low Cost Solar Array Project
The use of multiblade slurry sawing to produce silicon wafers from ingots was investigated. The commercially available state of the art process was improved by 20% in terms of area of silicon wafers produced from an ingot. The process was improved 34% on an experimental basis. Economic analyses presented show that further improvements are necessary to approach the desired wafer costs, mostly reduction in expendable materials costs. Tests which indicate that such reduction is possible are included, although demonstration of such reduction was not completed. A new, large capacity saw was designed and tested. Performance comparable with current equipment (in terms of number of wafers/cm) was demonstrated.
Fleming, J. R.↗
Reduction of computer usage costs in predicting unsteady aerodynamic loadings caused by control surface motions: Analysis and results
Results of theoretical and numerical investigations conducted to develop economical computing procedures were applied to an existing computer program that predicts unsteady aerodynamic loadings caused by leading and trailing edge control surface motions in subsonic compressible flow. Large reductions in computing costs were achieved by removing the spanwise singularity of the downwash integrand and evaluating its effect separately in closed form. Additional reductions were obtained by modifying the incremental pressure term that account for downwash singularities at control surface edges. Accuracy of theoretical predictions of unsteady loading at high reduced frequencies was increased by applying new pressure expressions that exactly satisified the high frequency boundary conditions of an oscillating control surface. Comparative computer result indicated that the revised procedures provide more accurate predictions of unsteady loadings as well as providing reduction of 50 to 80 percent in computer usage costs.
Rowe, W. S.↗
Sensitivities of projected 1980 photovoltaic system costs to major system cost drivers
The sensitivity of projected 1990 photovoltaic (PV) system costs to major system cost drivers was examined. It includes: (1) module costs and module efficiencies; (2) area related balance of system (BOS) costs; (3) inverter costs and efficiencies; and (4) module marketing and distribution markups and system integration fees. Recent PV system cost experiences and the high costs of electricity from the systems are reviewed. The 1990 system costs are projected for five classes of PV systems, including four ground mounted 5-MWp systems and one residential 5-kWp system. System cost projections are derived by first projecting costs and efficiencies for all subsystems and components. Sensitivity analyses reveal that reductions in module cost and engineering and system integration fees seem to have the greatest potential for contributing to system cost reduction. Although module cost is clearly the prime candidate for fruitful PV research and development activities, engineering and system integration fees seem to be more amenable to reduction through appropriate choice of system size and market strategy. Increases in inverter and module efficiency yield significant benefits, especially for systems with high area related costs.
Zimmerman, L. W.↗
Simultaneous Aerodynamic Analysis and Design Optimization (SAADO) for a 3-D Flexible Wing
The formulation and implementation of an optimization method called Simultaneous Aerodynamic Analysis and Design Optimization (SAADO) are extended from single discipline analysis (aerodynamics only) to multidisciplinary analysis - in this case, static aero-structural analysis - and applied to a simple 3-D wing problem. The method aims to reduce the computational expense incurred in performing shape optimization using state-of-the-art Computational Fluid Dynamics (CFD) flow analysis, Finite Element Method (FEM) structural analysis and sensitivity analysis tools. Results for this small problem show that the method reaches the same local optimum as conventional optimization. However, unlike its application to the win,, (single discipline analysis), the method. as I implemented here, may not show significant reduction in the computational cost. Similar reductions were seen in the two-design-variable (DV) problem results but not in the 8-DV results given here.
Gumbert, Clyde R.↗
Simultaneous Aerodynamic Analysis and Design Optimization (SAADO) for a 3-D Flexible Wing
The formulation and implementation of an optimization method called Simultaneous Aerodynamic Analysis and Design Optimization (SAADO) are extended from single discipline analysis (aerodynamics only) to multidisciplinary analysis - in this case, static aero-structural analysis and applied to a simple 3-D wing problem. The method aims to reduce the computational expense incurred in performing shape optimization using state-of-the-art Computational Fluid Dynamics (CFD) flow analysis, Finite Element Method (FEM) structural analysis and sensitivity analysis tools. Results for this small problem show that the method reaches the same local optimum as conventional optimization. However, unlike its application to the rigid wing (single discipline analysis), the method, as implemented here, may not show significant reduction in the computational cost. Similar reductions were seen in the two-design-variable (DV) problem results but not in the 8-DV results given here.
Gumbert, Clyde R.↗
A new VLSI architecture for a single-chip-type Reed-Solomon decoder
A new very large scale integration (VLSI) architecture for implementing Reed-Solomon (RS) decoders that can correct both errors and erasures is described. This new architecture implements a Reed-Solomon decoder by using replication of a single VLSI chip. It is anticipated that this single chip type RS decoder approach will save substantial development and production costs. It is estimated that reduction in cost by a factor of four is possible with this new architecture. Furthermore, this Reed-Solomon decoder is programmable between 8 bit and 10 bit symbol sizes. Therefore, both an 8 bit Consultative Committee for Space Data Systems (CCSDS) RS decoder and a 10 bit decoder are obtained at the same time, and when concatenated with a (15,1/6) Viterbi decoder, provide an additional 2.1-dB coding gain.
Hsu, I. S.↗
Simplifying silicon burning: Application of quasi-equilibrium to (alpha) network nucleosynthesis
While the need for accurate calculation of nucleosynthesis and the resulting rate of thermonuclear energy release within hydrodynamic models of stars and supernovae is clear, the computational expense of these nucleosynthesis calculations often force a compromise in accuracy to reduce the computational cost. To redress this trade-off of accuracy for speed, the authors present an improved nuclear network which takes advantage of quasi- equilibrium in order to reduce the number of independent nuclei, and hence the computational cost of nucleosynthesis, without significant reduction in accuracy. In this paper they will discuss the first application of this method, the further reduction in size of the minimal alpha network. The resultant QSE- reduced alpha network is twice as fast as the conventional alpha network it replaces and requires the tracking of half as many abundance variables, while accurately estimating the rate of energy generation. Such reduction in cost is particularly necessary for future generation of multi-dimensional models for supernovae.
Hix, W. R.↗
New technologies for solar energy silicon - Cost analysis of dichlorosilane process
A reduction in the cost of silicon for solar cells is an important objective in a project concerned with the reduction of the cost of electricity produced with solar cells. The cost goal for the silicon material is about $14 per kg (1980 dollars). The process which is currently employed to produce semiconductor grade silicon from trichlorosilane is not suited for meeting this cost goal. Other processes for producing silicon are, therefore, being investigated. A description is presented of results obtained for the DCS process which involves the production of dichlorosilane as a silicon source material for solar energy silicon. Major benefits of dichlorosilane as a silicon source material include faster reaction rates for chemical vapor deposition of silicon. The DCS process involves the reaction 2SiHCl3 yields reversibly SiH2Cl2 + SiCl4. The results of a cost analysis indicate a total product cost without profit of $1.29/kg of SiH2Cl2.
Yaws, C. L.↗
Low-Noise Spiral Bevel Gears
Modified spiral bevel gears that generate relatively little noise and vibration designed and fabricated for use in U.S. Army OH-58D helicopter. Noise reduced by 12 to 19 dB. Similar low-noise, low-vibration spiral bevel gears used in other helicopters, with consequent benefits in comfort and health of pilots and passengers, enhancement of pilots' performance and safety through reduction of audible distraction, and reduction in cost and weight of helicopters through reduction in amount of sound-proofing material. Low-noise, low-vibration spiral bevel gears also used in drive axles of cars and trucks for smoother, quieter rides.
Lewicki, David G.↗
Low cost payload studies
Low cost payload studies aimed at the reduction of Space Shuttle cost, with the emphasis on mission support subsystem equipment, are reviewed. Spacecraft design, manufacturing and operational approaches are specified and quantified to demonstrate the feasibility of reductions of cost from present-day estimates. Space Shuttle design capabilities for retrieval, repair, and reuse of future payloads are indicated as cost reduction possibilities. It is also pointed out that an increased volume and weight carrying capability of the Space Shuttle can alter the design approach to future payloads to reduce cost. Details are given on some specific subsystem component design alterations integrated in an overall low-cost payload design. Refurbishment is discussed as the final area of interest for low cost payload design. Total program savings of up to 50% are found to be possible in the studies.
Moore, W. F.↗
Reduction of computer usage costs in predicting unsteady aerodynamic loadings caused by control surface motion. Addendum to computer program description
Changes to be made that provide increased accuracy and increased user flexibility in prediction of unsteady loadings caused by control surface motions are described. Analysis flexibility is increased by reducing the restrictions on the location of the downwash stations relative to the leading edge and the edges of the control surface boundaries. Analysis accuracy is increased in predicting unsteady loading for high Mach number analysis conditions through use of additional chordwise downwash stations. User guideline are presented to enlarge analysis capabilities of unusual wing control surface configurations. Comparative results indicate that the revised procedures provide accurate predictions of unsteady loadings as well as providing reductions of 40 to 75 percent in computer usage cost required by previous versions of this program.
Rowe, W. S.↗
Evaluation of Contrail Reduction Strategies Based on Environmental and Operational Costs
This paper evaluates a set of contrail reduction strategies based on environmental and operational costs. A linear climate model was first used to convert climate effects of carbon dioxide emissions and aircraft contrails to changes in Absolute Global Temperature Potential, a metric that measures the mean surface temperature change due to aircraft emissions and persistent contrail formations. The concept of social cost of carbon and the carbon auction price from recent California's cap-and-trade system were then used to relate the carbon dioxide emissions and contrail formations to an environmental cost index. The strategy for contrail reduction is based on minimizing contrail formations by altering the aircraft's cruising altitude. The strategy uses a user-defined factor to trade off between contrail reduction and additional fuel burn and carbon dioxide emissions. A higher value of tradeoff factor results in more contrail reduction but also more fuel burn and carbon emissions. The strategy is considered favorable when the net environmental cost benefit exceeds the operational cost. The results show how the net environmental benefit varies with different decision-making time-horizon and different carbon cost. The cost models provide a guidance to select the trade-off factor that will result in the most net environmental benefit.
social cost of carbon↗
Concepts for reducing exhaust emissions and fuel consumption of the aircraft piston engine
A study was made to reduce exhaust emissions and fuel consumption of a general aviation aircraft piston engine by applying known technology. Fourteen promising concepts such as stratified charge combustion chambers, cooling cylinder head improvements, and ignition system changes were evaluated for emission reduction and cost effectiveness. A combination of three concepts, improved fuel injection system, improved cylinder head with exhaust port liners and exhaust air injection was projected as the most cost effective and safe means of meeting the EPA standards for CO, HC and NO. The fuel economy improvement of 4.6% over a typical single engine aircraft flight profile does not though justify the added cost of the three concepts, and significant reductions in fuel consumption must be applied to the cruise mode where most of the fuel is used. The use of exhaust air injection in combination with exhaust port liners reduces exhaust valve stem temperatures which can result in longer valve guide life. The use of exhaust port liners alone can reduce engine cooling air requirements by 11% which is the equivalent of a 1.5% increase in propulsive power. The EPA standards for CO, HC and NO can be met in the IO-520 engine using air injection alone or the Simmonds improved fuel injection system.
Rezy, B. J.↗
Application of Reconfigurable Avionics for the Bantam Launch Vehicle
The modern market is placing increasing pressure on launch costs. This is particularly true for small university science payloads, where the cost of the experiment itself is relatively low, and the launch frequency is potentially very high. It is the stated goal of the Bantam Program to dramatically reduce the costs of launching this class of payloads. This is a goal that will require that the avionics not only be reduced in production costs, but also in maintenance and operation costs, because the Bantam vehicle is envisioned as a reusable launch system. However, the costs of avionics is a relatively small fraction of the overall cost of launching a payload, and a simple reduction in the avionics costs will not immediately realize the necessary gains. Instead, to reduce the total system launch costs, it is also necessary to improve avionics performance. Only by reducing weight, volume, and power, while enhancing computational capability can the avionics be used to address the system-level cost reduction requirements. The National Aeronautics and Space Administration is currently pursuing technology development tasks, in order to support the Bantam requirements. One technology task is to develop a low-cost, high-performance reconfigurable avionics core unit. In addition to providing low cost and high performance, the use of reconfigurability will be used to explore the options of accommodating multiple launch configurations, and addressing such areas as redundancy management, single-event upset immunity, and low maintenance. This paper will address how emerging developments in reconfigurable avionics can be used to meet these challenges.
Wallace, Shawn↗
Variable polarity plasma arc welding on the Space Shuttle external tank
Variable polarity plasma arc (VPPA) techniques used at NASA's Marshall Space Flight Center for the fabrication of the Space Shuttle External Tank are presentedd. The high plasma arc jet velocities of 300-2000 m/s are produced by heating the plasma gas as it passes through a constraining orifice, with the plasma arc torch becoming a miniature jet engine. As compared to the GTA jet, the VPPA has the following advantages: (1) less sensitive to contamination, (2) a more symmetrical fusion zone, and (3) greater joint penetration. The VPPA welding system is computerized, operating with a microprocessor, to set welding variables in accordance with set points inputs, including the manipulator and wire feeder, as well as torch control and power supply. Some other VPPA welding technique advantages are: reduction in weld repair costs by elimination of porosity; reduction of joint preparation costs through elimination of the need to scrape or file faying surfaces; reduction in depeaking costs; eventual reduction of the 100 percent-X-ray inspection requirements. The paper includes a series of schematic and block diagrams.
Nunes, A. C., Jr.↗
Reduction of computer usage costs in predicting unsteady aerodynamic loadings caused by control surface motions: Computer program description
A digital computer program was developed to calculate unsteady loadings caused by motions of lifting surfaces with leading edge and trailing edge controls based on the subsonic kernel function approach. The pressure singularities at hinge line and side edges were extracted analytically as a preliminary step to solving the integral equation of collocation. The program calculates generalized aerodynamic forces for user supplied deflection modes. Optional intermediate output includes pressure at an array of points, and sectional generalized forces. From one to six controls on the half span can be accomodated.
Petrarca, J. R.↗