Virtual mission systems for multi-disciplinary engineering system design
To ensure the science return while minimizing the cost and risk of a mission, a lifecycle-wide concurrent engineering design process must be established.
operation↗
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Results for “Process engineering”
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.
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In the soft-to-hard technical spectrum: Where is software engineering?
In the computer journals and tabloids, there have been a plethora of articles written about the software engineering field. But while advocates of the need for an engineering approach to software development, it is impressive how many authors have treated the subject of software engineering without adequately addressing the fundamentals of what engineering as a discipline consists of. A discussion is presented of the various related facets of this issue in a logical framework to advance the thesis that the software development process is necessarily an engineering process. The purpose is to examine more of the details of the issue of whether or not the design and development of software for digital computer processing systems should be both viewed and treated as a legitimate field of professional engineering. Also, the type of academic and professional level education programs that would be required to support a software engineering discipline is examined.
Leibfried, Theodore F.↗
The Isothermal Dendritic Growth Experiment
The growth of dendrites is one of the commonly observed forms of solidification encountered when metals and alloys freeze under low thermal gradients, as occurs in most casting and welding processes. In engineering alloys, the details of the dendritic morphology directly relates to important material responses and properties. Of more generic interest, dendritic growth is also an archetypical problem in morphogenesis, where a complex pattern evolves from simple starting conditions. Thus, the physical understanding and mathematical description of how dendritic patterns emerge during the growth process are of interest to both scientists and engineers. The Isothermal Dendritic Growth Experiment (IDGE) is a basic science experiment designed to measure, for a fundamental test of theory, the kinetics and morphology of dendritic growth without complications induced by gravity-driven convection. The IDGE, a collaboration between Rensselaer Polytechnic Institute, in Troy NY, and NASA's Lewis Research Center (LeRC) was developed over a ten year period from a ground-based research program into a space flight experiment. Important to the success of this flight experiment was provision of in situ near-real-time teleoperations during the spaceflight experiment.
Glicksman, M. E.↗
New Method Developed to Measure Contact Angles of a Sessile Drop
The spreading of an evaporating liquid on a solid surface occurs in many practical processes and is of importance in a number of practical situations such as painting, textile dyeing, coating, gluing, and thermal engineering. Typical processes involving heat transfer where the contact angle plays an important role are film cooling, boiling, and the heat transfer through heat pipes. The biological phenomenon of cell spreading also is analogous to a drop spreading (ref. 1). In the study of spreading, the dynamic contact angle describes the interfacial properties on solid substrates and, therefore, has been studied by physicists and fluid mechanics investigators. The dynamic contact angle of a spreading nonvolatile liquid drop provides a simple tool in the study of the free-boundary problem, but the study of the spreading of a volatile liquid drop is of more practical interest because the evaporation of common liquids is inevitable in practical processes. The most common method to measure the contact angle, the contact radius, and the height of a sessile drop on a solid surface is to view the drop from its edge through an optical microscope. However, this method gives only local information in the view direction. Zhang and Yang (ref. 2) developed a laser shadowgraphy method to investigate the evaporation of sessile drop on a glass plate. As described here, Zhang and Chao (refs. 3 and 4) improved the method and suggested a new optical arrangement to measure the dynamic contact angle and the instant evaporation rate of a sessile drop with much higher accuracy (less than 1 percent). With this method, any fluid motion in the evaporating drop can be visualized through shadowgraphy without using a tracer, which often affects the field under investigation.
Chao, David F.↗
Lightweight, strong, moldable wood via cell wall engineering as a sustainable structural material
Turning wood into honeycombs Wood is an attractive material for structural applications, but it usually works best as boards or sheets. Xiao et al . have developed a process for engineering hardwood that allows these sheets to be manipulated into complex structures (see the Perspective by Tajvidi and Gardner). The key is to manipulate the cell wall structure by shrinking and blasting open the fibers and vessels by drying and “water-shocking” them. This process creates a window wherein the wood can be manipulated without ripping or tearing. Honeycomb, corrugated, or other complex structures are locked in once the wood dries. —BG
Science & Technology - Other Topics↗
The Digital Engineering Vision for DOME: Facilitating Design, Deployment, and Operations [Poster]
DOME is a planned microreactor test facility at INL’s Materials and Fuels Complex. It is a complex system with several interdependent sub-systems such as the reactor (up to 20 MWth), radioactive confinement, temperature and pressure regulation system, ventilation system, etc. The engineering design process for such a system traditionally involves several documents from various sources and the system information is scattered across these documents. Digital engineering represents a paradigm shift through which systems are designed using digital models and integrated data. The digital engineering vision for DOME utilizes a model-based systems engineering (MBSE) approach. The system architecture, physical components, control logic, and verification experiments are all designed using MathWorks MATLAB and Simulink. This hierarchical model can combine data from multiple sources at various levels of abstraction. It can be used to simulate the facility’s operations and to test the system using different sets of parameters. Its capabilities can be expanded by interfacing it with high-fidelity multi-physics models, risk analysis tools, etc. The same model can evolve into a digital twin that can monitor operations and conduct predictive analysis using real-time sensor data from the facility. The eventual goal of this effort is to transform the end-to-end engineering of nuclear facilities in every phase of their lifecycle, including design, deployment, and operations.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
SinhaRoy_TechPresentation_2024 [Slides]
DOME is a planned microreactor test facility at INL’s Materials and Fuels Complex. It is a complex system with several interdependent sub-systems such as the reactor (up to 20 MWth), radioactive confinement, temperature and pressure regulation system, ventilation system, etc. The engineering design process for such a system traditionally involves several documents from various sources and the system information is scattered across these documents. Digital engineering represents a paradigm shift through which systems are designed using digital models and integrated data. The digital engineering vision for DOME utilizes a model-based systems engineering (MBSE) approach. The system architecture, physical components, control logic, and verification experiments are all designed using MathWorks MATLAB and Simulink. This hierarchical model can combine data from multiple sources at various levels of abstraction. It can be used to simulate the facility’s operations and to test the system using different sets of parameters. Its capabilities can be expanded by interfacing it with high-fidelity multi-physics models, risk analysis tools, etc. The same model can evolve into a digital twin that can monitor operations and conduct predictive analysis using real-time sensor data from the facility. The eventual goal of this effort is to transform the end-to-end engineering of nuclear facilities in every phase of their lifecycle, including design, deployment, and operations.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Model-Based Systems Engineering for Capturing Mission Architecture System Processes with an Application Case Study - Orion Flight Test 1
Model-based Systems Engineering (MBSE) is an emerging methodology that can be leveraged to enhance many system development processes. MBSE allows for the centralization of an architecture description that would otherwise be stored in various locations and formats, thus simplifying communication among the project stakeholders, inducing commonality in representation, and expediting report generation. This paper outlines the MBSE approach taken to capture the processes of two different, but related, architectures by employing the Systems Modeling Language (SysML) as a standard for architecture description and the modeling tool MagicDraw. The overarching goal of this study was to demonstrate the effectiveness of MBSE as a means of capturing and designing a mission systems architecture. The first portion of the project focused on capturing the necessary system engineering activities that occur when designing, developing, and deploying a mission systems architecture for a space mission. The second part applies activities from the first to an application problem - the system engineering of the Orion Flight Test 1 (OFT-1) End-to-End Information System (EEIS). By modeling the activities required to create a space mission architecture and then implementing those activities in an application problem, the utility of MBSE as an approach to systems engineering can be demonstrated.
Orion Flight Test 1 (OFT-1)↗
Human Systems Integration: Managing Risk in Anesthesia
The practice of anesthesia relies on clinicians’ ability to safely manage increasingly complex equipment. Devices such as ventilators, drug infusion pumps, and physiologic monitors use sophisticated algorithms to deliver care, but most clinicians are only trained to manage automated systems during normal operation. Few if any receive training on how to manage system failures. Although manufacturers are required to consult with human factors engineers as part of the equipment design process, most pieces of equipment are ultimately brought to market without extensive input from clinicians. Systems in the operating room can be as simple as an oxygen tank, or as complex as a multi-institutional healthcare organization. Humans are also a complex system, and play a critical role in the domains of operations, design, fabrication, maintenance, repair, and ultimately, dismantling and closeout. HSI seeks to provide a means for advocating the human side of the system. Human Systems Integration (HSI) is the cross disciplinary process used as part of the Systems Engineering process to reduce risk in systems. HSI professionals consider the human, hardware, and software elements of system design to optimize system performance and improve safety. HSI professionals work in domains of study that include training, management, human factors engineering, safety, and occupational health, among others. This article discusses the role of systems in the practice of anesthesia, and how consideration of the human during all phases of the system life cycle helps manage risks and promote a better patient outcome.
Human Factors↗
Meanline Analysis of Turbines with Choked Flow in the Object-Oriented Turbomachinery Analysis Code
The prediction of turbomachinery performance characteristics is an important part of the conceptual aircraft engine design process. During this phase, the designer must examine the effects of a large number of turbomachinery design parameters to determine their impact on overall engine performance and weight. The lack of detailed design information available in this phase necessitates the use of simpler meanline and streamline methods to determine the turbomachinery geometry characteristics and provide performance estimates prior to more detailed CFD (Computational Fluid Dynamics) analyses. While a number of analysis codes have been developed for this purpose, most are written in outdated software languages and may be difficult or impossible to apply to new, unconventional designs. The Object-Oriented Turbomachinery Analysis Code (OTAC) is currently being developed at NASA Glenn Research Center to provide a flexible meanline and streamline analysis capability in a modern object-oriented language. During the development and validation of OTAC, a limitation was identified in the code's ability to analyze and converge turbines as the flow approached choking. This paper describes a series of changes which can be made to typical OTAC turbine meanline models to enable the assessment of choked flow up to limit load conditions. Results produced with this revised model setup are provided in the form of turbine performance maps and are compared to published maps.
Choked Flow↗
Direct Air Capture of CO 2 Using Solvents
Large-scale deployment of negative emissions technologies (NETs) that permanently remove CO 2 from the atmosphere is now considered essential for limiting the global temperature increase to less than 2°C by the end of this century. One promising NET is direct air capture (DAC), a technology that employs engineered chemical processes to remove atmospheric carbon dioxide, potentially at the scale of billions of metric tons per year. This review highlights one of the two main approaches to DAC based on aqueous solvents. The discussion focuses on different aspects of DAC with solvents, starting with the fundamental chemistry that includes the chemical species and reactions involved and the thermodynamics and kinetics of CO 2 binding and release. Chemical engineering aspects are also discussed, including air–liquid contactor design, process development, and technoeconomic assessments to estimate the cost of the DAC technologies. Various solvents employed in DAC are reviewed, from aqueous alkaline solutions (NaOH, KOH) to aqueous amines, amino acids, and peptides, along with different solvent regeneration methods, from the traditional thermal swinging to the more exploratory carbonate crystallization with guanidines or electrochemical methods.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Human Factors Interface with Systems Engineering for NASA Human Spaceflights
This paper summarizes the past and present successes of the Habitability and Human Factors Branch (HHFB) at NASA Johnson Space Center s Space Life Sciences Directorate (SLSD) in including the Human-As-A-System (HAAS) model in many NASA programs and what steps to be taken to integrate the Human-Centered Design Philosophy (HCDP) into NASA s Systems Engineering (SE) process. The HAAS model stresses systems are ultimately designed for the humans; the humans should therefore be considered as a system within the systems. Therefore, the model places strong emphasis on human factors engineering. Since 1987, the HHFB has been engaging with many major NASA programs with much success. The HHFB helped create the NASA Standard 3000 (a human factors engineering practice guide) and the Human Systems Integration Requirements document. These efforts resulted in the HAAS model being included in many NASA programs. As an example, the HAAS model has been successfully introduced into the programmatic and systems engineering structures of the International Space Station Program (ISSP). Success in the ISSP caused other NASA programs to recognize the importance of the HAAS concept. Also due to this success, the HHFB helped update NASA s Systems Engineering Handbook in December 2007 to include HAAS as a recommended practice. Nonetheless, the HAAS model has yet to become an integral part of the NASA SE process. Besides continuing in integrating HAAS into current and future NASA programs, the HHFB will investigate incorporating the Human-Centered Design Philosophy (HCDP) into the NASA SE Handbook. The HCDP goes further than the HAAS model by emphasizing a holistic and iterative human-centered systems design concept.
Wong, Douglas T.↗
Integration of safety engineering into a cost optimized development program.
A six-segment management model is presented, each segment of which represents a major area in a new product development program. The first segment of the model covers integration of specialist engineers into 'systems requirement definition' or the system engineering documentation process. The second covers preparation of five basic types of 'development program plans.' The third segment covers integration of system requirements, scheduling, and funding of specialist engineering activities into 'work breakdown structures,' 'cost accounts,' and 'work packages.' The fourth covers 'requirement communication' by line organizations. The fifth covers 'performance measurement' based on work package data. The sixth covers 'baseline requirements achievement tracking.'
Ball, L. W.↗
Criticality Safety Evaluation Project Development for University of California Berkely Nuclear Criticality Safety Pipeline Course
The Nuclear Criticality Safety Division at Lawrence Livermore National Laboratory (LLNL) has taken a unique approach to developing criticality safety evaluation topics in support of the University of California Berkeley criticality safety pipeline course. The evaluation topics are designed to go beyond the typical evaluation examples used for many training courses including vault storage and variations on storage arrays. These types of evaluations provide in-depth analysis into the fundamentals of criticality safety and are complex but may be far off from what a new criticality safety engineer may actually be evaluating. To provide more practical examples of criticality safety evaluation topics that are better fit for the knowledge level of a criticality safety engineer in-training, variations of current and future operations and research operations performed at LLNL are used as evaluation topics. Additionally, an emphasis on research is included in all evaluation topics as it allows students to take advantage of the concepts learned in class to apply them for process improvement, engineering equipment that is favorable for criticality safety, and negotiation tactics to work with operations personnel. The process used by LLNL to develop project topics for the pipeline course is provided in this paper. The intent is to provide an alternative technique for training students and potentially younger staff members in criticality safety on developing criticality safety evaluations.
42 ENGINEERING↗
Characterization and Analyses of Valves, Feed Lines and Tanks used in Propellant Delivery Systems at NASA SSC
Accurate modeling of liquid rocket engine test processes involves assessing critical fluid mechanic and heat and mass transfer mechanisms within a cryogenic environment, and accurately modeling fluid properties such as vapor pressure and liquid and gas densities as a function of pressure and temperature. The Engineering and Science Directorate at the NASA John C. Stennis Space Center has developed and implemented such analytic models and analysis processes that have been used over a broad range of thermodynamic systems and resulted in substantial improvements in rocket propulsion testing services. In this paper, we offer an overview of the analyses techniques used to simulate pressurization and propellant fluid systems associated with the test stands at the NASA John C. Stennis Space Center. More specifically, examples of the global performance (one-dimensional) of a propellant system are provided as predicted using the Rocket Propulsion Test Analysis (RPTA) model. Computational fluid dynamic (CFD) analyses utilizing multi-element, unstructured, moving grid capability of complex cryogenic feed ducts, transient valve operation, and pressurization and mixing in propellant tanks are provided as well.
Ryan, Harry M.↗
Impacts of the Additive Manufacturing Process on the Roughness of Engine Scale Vanes and Cooling Channels
Abstract By leveraging the additive manufacturing (AM) platform, development time and costs for turbine component testing can be reduced relative to traditional investment casting. Surface roughness is a key characteristic of the additive manufacturing process that can impact flow, heat transfer, and mechanical integrity of printed components. There are multiple design and build considerations that result in variability in surface roughness, especially when additively fabricating complicated three-dimensional vanes and internal cooling passages. This study characterizes the surface roughness of internal cooling passages, vanes, and flat external surface samples made using additive manufacturing, specifically the direct metal laser sintering process. The samples were manufactured with various wall thicknesses, layer thicknesses, build locations, build directions, and on different AM machines. A combination of computed tomography scanning and optical profilometry was used to evaluate surface roughness levels. The data indicate that the dominant factors in roughness for a given layer thickness are a function of wall thickness, build location, and build direction.
Engineering↗
General Pressurization Model in Simscape
System integration is an essential part of the engineering design process. The Ares I Upper Stage (US) is a complex system which is made up of thousands of components assembled into subsystems including a J2-X engine, liquid hydrogen (LH2) and liquid oxygen (LO2) tanks, avionics, thrust vector control, motors, etc. System integration is the task of connecting together all of the subsystems into one large system. To ensure that all the components will "fit together" as well as safety and, quality, integration analysis is required. Integration analysis verifies that, as an integrated system, the system will behave as designed. Models that represent the actual subsystems are built for more comprehensive analysis. Matlab has been an instrument widely use by engineers to construct mathematical models of systems. Simulink, one of the tools offered by Matlab, provides multi-domain graphical environment to simulate and design time-varying systems. Simulink is a powerful tool to analyze the dynamic behavior of systems over time. Furthermore, Simscape, a tool provided by Simulink, allows users to model physical (such as mechanical, thermal and hydraulic) systems using physical networks. Using Simscape, a model representing an inflow of gas to a pressurized tank was created where the temperature and pressure of the tank are measured over time to show the behavior of the gas. By further incorporation of Simscape into model building, the full potential of this software can be discovered and it hopefully can become a more utilized tool.
Servin, Mario↗
Probabalistic Risk Analysis and Thermal Margin Process for an Inflatable Aeroshell
Uncertainties always exist in atmospheric entry aeroheating environments and the thermal response of thermal protection system (TPS) material. These uncertainties are mitigated in the design by ap-plying margin and factors of safety to the TPS. Entry vehicle TPS is often conservatively over-sized for the heat loads that are experienced along the entry trajectory by stacking worst-case scenarios together. Additionally, the current TPS design and margin process used by NASA offers very little insight into the risk of over-temperature during flight and the reliability of the heat shield performance [1,3]. A probabilistic margin process can be used to calculate the amount of TPS margin necessary to survive a given entry heat load at a specified level of risk [2,3,4]. The vehicle’s initial entry state (entry velocity, flight path angle, and entry mass) determines the expected atmospheric entry environmental conditions and resulting heat load that the entry vehicle will experience. If there is flexibility in the entry state, then this process can be used to select an appropriate combination of entry state parameters and TPS size to target a desired reentry reliability. This probabilistic margin process allows engineers to make informed aeroshell design, entry-trajectory design, and TPS performance risk trades while preventing excessive TPS margin from being applied. The probabilistic TPS margin process has been performed to determine TPS thickness and entry heating constraints given an acceptable risk level for the Low Earth Orbit Flight Experiment of an Inflatable Decelerator (LOFTID) flight project. The process is used in a manner to size the entry heat load for a given flexible TPS (FTPS) thickness so that it meets project reliability standards while allowing the FTPS and the underlying inflatable structure (IS) to be pushed to adequately high temperatures. Since the LOFTID project is an experimental flight demonstration, it is de-sired to drive the FTPS and IS to temperatures that cover a large range of their thermal response models’ applicability. This will allow the thermal response models to be better improved and validated post-flight using LOFTID’s extensive instrumentation embedded within the aeroshell. The presentation demonstrates how uncertainty analysis is carried out using an end-to-end Monte Carlo process where three separate Monte Carlo simulations are run in sequence. The first Monte Carlo simulation operates on the entry trajectory model to generate trajectory parameter dispersions that are fed into the second Monte Carlo simulation. The second Monte Carlo simulation operates on the aerothermodynamics model to generate aeroheating parameter dispersions that are fed into the third Monte Carlo simulation. The third Monte Carlo simulation operates on the FTPS material thermal response model to generate the final FTPS/IS thermal response dispersions. The end-to-end Monte Carlo simulation propagates the uncertainties of each model into the next to quantify the resulting uncertainty of the FTPS/IS thermal response. The fractional contributions of the uncertain parameters in the trajectory, aerothermal, and thermal response models to the variance in the FTPS/IS thermal response is determined as a byproduct of the Monte Carlo analysis. The structural uncertainty of the FTPS thermal response model is evaluated by flight relevant ground testing and model error analysis using test measurements. This probabilistic TPS margin process had never been applied to an entry vehicle and it is one of the LOFTID project’s goals to demonstrate its merits.
Steven A. Tobin↗